Extended-range automobile body and manufacturing method thereof

Abstract

The invention relates to a range extending type automobile body and a manufacturing method thereof.The automobile body comprises a front cabin assembly, a floor assembly and a range extender assembly, the front cabin assembly is provided with a first suspension and a second suspension, the floor assembly comprises a middle channel, and the middle channel is provided with a third suspension; the third suspension is spaced apart from the first suspension and the second suspension in front-rear and up-down directions, respectively. And drawing forming machining is conducted on the floor assembly blank to form a floor body and a middle channel, a material storage convex hull is formed on the middle channel, shaping machining is conducted on the floor blank, and the arc length of the material storage convex hull is equal to that of the corresponding arc-shaped corner. According to the structure and the manufacturing method, the assembly position tolerance is reduced to be within 2 mm, the amplitude of the range extender assembly in the driving process is reduced, the vehicle failure rate is reduced by 20%, and noise is reduced by 3 dB. The range extender assembly manufactured through the method can adapt to various vehicle types, the utilization rate of the space in the vehicle is increased, the space of a passenger compartment is increased by 170 mm, the system mode is improved to 316 Hz, and the supporting strength of the range extender assembly is improved by 30%.

Description

[0001] This application claims priority to the Chinese patent application filed with the State Intellectual Property Office of China on September 12, 2024, with application number 202411277628.6 and invention name “Vehicle”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the field of vehicle technology, and in particular to a range-extended vehicle body and a method for manufacturing the same. Background Art

[0003] With rising environmental awareness and the pursuit of energy sustainability, the new energy vehicle market is booming. Extended-range vehicles (ERVs), with their unique advantages such as longer driving range, lower energy consumption, and superior driving experience, are gradually emerging in the market and gaining increasing consumer favor. Among the key components of ERVs, the range extender assembly plays a crucial role. As the vehicle's power generation core, it provides a solid foundation for the vehicle's power supply. Its performance and stability directly impact the vehicle's driving performance and user experience.

[0004] In the prior art, the installation structure of the range extender assembly has always been a key issue of concern in the industry. For example, the patent document with publication number CN208702594U proposes an integrated motor structure with a starter, which connects the engine output end to the motor housing through a connecting plate, and the front end of the rotor bracket is connected to the end face of the engine output shaft. However, this solution has the defect of a long overall length of the motor, which not only makes it difficult to arrange it in the limited front cabin space of the vehicle, but also increases the weight of the vehicle, affecting energy utilization efficiency. In addition, the patent document with publication number CN215971079U focuses on the suspension structure of the range-extended hybrid box. This patent attempts to solve some problems through a specific suspension design, but there are still shortcomings. Although the suspension structure takes vibration attenuation into account to a certain extent, due to its relatively complex design, it requires more components to achieve the intended function, which not only increases the manufacturing cost, but also increases the difficulty of subsequent maintenance. Internationally, there are also patents related to range extender assemblies, such as German patent publication number DE102009057693A, which covers a hybrid vehicle. The range extender's connection to the vehicle chassis is relatively traditional, primarily using a rigid connection. While this ensures a secure connection, it provides poor vibration dampening. When the vehicle travels over bumpy roads, the vibrations generated by the range extender are directly transmitted to the vehicle body, reducing ride comfort and potentially causing loosening and wear of related body components due to prolonged vibration, impacting vehicle reliability.

[0005] Overall, in the relevant existing technologies, due to the generally large size of the range extender assembly in extended-range vehicles, the range extender assembly is prone to significant displacement or rotation during driving, resulting in large vibration amplitudes, which can easily affect the vehicle body and cab, seriously affecting the interior comfort. It may also cause long-term damage to the body structure and reduce the overall safety and durability of the vehicle. Therefore, how to optimize the installation structure of the range extender assembly to reduce its displacement, rotation, and vibration during driving and maintain the stability and reliability of the range extender assembly operation has become a technical problem that needs to be solved urgently. Summary of the Invention

[0006] The present application provides a range-extended vehicle body and a manufacturing method thereof, which solves the problem that the range extender assembly of the range-extended vehicle is prone to large displacement or rotation during driving, resulting in large vibration amplitude, which is easy to affect the body and cab.

[0007] In order to achieve the above objectives, the main technical solutions adopted in this application include:

[0008] A first aspect of an embodiment of the present application provides a range-extended automobile body, comprising a front cabin assembly, a floor assembly, and a range extender assembly, wherein a first suspension and a second suspension are provided on the front cabin assembly, the first suspension and the second suspension are spaced apart in the left-right direction, the floor assembly is located behind the front cabin assembly, the floor assembly comprises a floor body and a middle channel provided on the floor body, a third suspension is provided on the middle channel, the third suspension is spaced apart from the first suspension and the second suspension in the front-to-back direction, respectively, and the third suspension is spaced apart from the first suspension and the second suspension in the up-down direction, respectively, and the range extender assembly is fixed to the front cabin assembly and the floor assembly through the first suspension, the second suspension, and the third suspension.

[0009] Because the first, second, and third mounts together form a triangular structure to secure the range extender assembly, the triangular mount design allows the three mounting points to be evenly spaced around the range extender assembly, forming a stable triangular support structure. This effectively resists various torsional and vibrational forces exerted on the range extender assembly during driving, thereby maintaining the stability and reliability of the range extender assembly and improving the safety and reliability of the vehicle. Furthermore, the triangular mount attenuates vibrations generated by the range extender assembly during operation, reducing their impact on other components of the range extender vehicle, improving vehicle noise levels, and enhancing vehicle comfort. For example, it can reduce noise levels by 3 decibels, enhancing vehicle comfort.

[0010] The third mount is separated vertically from the first and second mounts, improving vehicle stability and maneuverability and suppressing longitudinal vibration of the range extender assembly. This layout enhances vibration isolation, reduces the impact of vibration on the range-extended vehicle body and cab, lowers the probability of vehicle failure, and improves operational stability. For example, it can reduce the probability of vehicle failure by 20%, improve operational stability, and lower user costs.

[0011] Furthermore, the range extender assembly in the embodiment of the present application can be assembled with the first, second, and third mounts before being integrated with the front cabin assembly and floor assembly. This allows the relative positions of the individual mounting points in the free state to meet the composite positional accuracy requirements, reducing the positional tolerance during assembly and ensuring the positional accuracy of the range extender assembly. For example, the positional tolerance can be reduced to within 2 mm to ensure the positional accuracy of the range extender assembly.

[0012] Optionally, the third suspension includes a bushing seat, an elastic member and an inner core, the elastic member is installed in the bushing seat, and the inner core is installed in the elastic member; the inner core is provided with a first mounting hole, the middle channel is provided with a third suspension mounting bracket, and the third suspension mounting bracket is provided with a second mounting hole; the second mounting hole is connected to the first mounting hole by a mounting bolt.

[0013] The first mounting hole on the inner core of the third suspension is connected to the second mounting hole on the third suspension mounting bracket via mounting bolts, resulting in a high-strength connection, a simple structure, and ease of implementation. The elastic member disposed between the bushing seat and the inner core can adaptively reduce vibration of the range extender assembly during operation, thereby providing a good buffering effect during vibration of the range extender assembly, reducing the impact of vibration of the range extender assembly on the body of the range extender vehicle, improving the stability of the range extender vehicle, and preventing collision between the inner core and the bushing seat during operation of the range extender, thereby reducing noise.

[0014] Optionally, the diameter of the first mounting hole is larger than the diameter of the mounting bolt, and / or the center position of the first mounting hole is lower than the center position of the second mounting hole in the up-down direction.

[0015] The diameter of the first mounting hole is larger than that of the mounting bolt, allowing the mounting bolt to move vertically within the first mounting hole. This allows the range extender assembly, after assembly, to be pulled by the range extender's own weight, thereby allowing the mounting bolt to contact the inner wall of the first mounting hole. Furthermore, the larger diameter of the first mounting hole facilitates the matching installation of the mounting bolt, reducing the difficulty of bolt installation and improving installation convenience.

[0016] After the range extender assembly is assembled, the third mount can be pulled downward by the weight of the range extender assembly itself, so that the mounting bolt fits into the inner wall surface of the first mounting hole, thereby improving structural stability, and being able to drive the third mount to a more precise installation position, thereby improving the installation accuracy of the third mount and avoiding positional interference between the third mount and other components.

[0017] Optionally, the elastic member includes a mounting portion and a connecting arm, one end of the connecting arm is connected to the inner wall of the bushing seat, and the other end of the connecting arm is connected to the mounting portion; the mounting portion includes a mounting cavity, and the inner core is installed in the mounting cavity.

[0018] The inner core is positioned within the mounting cavity of the mounting portion, enhancing the stability of the connection between the inner core and the elastic member. After the range extender assembly is assembled, the inner core is displaced by the vibration of the range extender assembly. The connecting arm, connected between the bushing seat and the mounting portion, provides reverse tension and buffering force for the inner core. This adaptively reduces vibration during operation, preventing excessive vibration of the inner core and the range extender assembly, and thus providing a good buffering effect during vibration of the range extender assembly.

[0019] Optionally, the inner core includes a first arcuate surface, a second arcuate surface and a connecting surface connected between the first arcuate surface and the second arcuate surface; the diameter of the first arcuate surface is larger than the diameter of the second arcuate surface, and the connecting arm is connected to the corresponding positions of the second arcuate surface and the connecting surface on the mounting portion.

[0020] The first curved surface has a larger diameter, which allows the inner core to have sufficient volume to accommodate the corresponding positioning holes and mounting holes, thereby increasing the overall strength of the inner core, preventing damage to the inner core due to stress, and improving the structural stability of the third suspension. Furthermore, the second curved surface has a smaller diameter than the first curved surface, and the connecting arm is connected to the corresponding positions of the second curved surface and the connecting surface on the mounting portion. This increases the volume of the connecting arm, thereby enhancing the cushioning effect of the connecting arm, and increases the connection area between the connecting arm and the corresponding inner core on the mounting portion, thereby preventing excessive stress concentration on the connecting arm from the inner core, improving the fatigue durability of the connecting arm, and extending the service life of the elastic member.

[0021] Optionally, the elastic member further includes a first buffer portion and a second buffer portion, a first gap is formed between the first buffer portion and the connecting arm and the mounting portion; a second gap is formed between the second buffer portion and the connecting arm and the mounting portion, and the first gap and the second gap are spaced apart in the up and down directions.

[0022] The setting of the first gap and the second gap can provide a buffer space for the inner core to move with the vibration of the range extender assembly, further reducing the force transmitted by the inner core to the first buffer part and the second buffer part, improving the buffering effect, reducing the impact of the vibration of the range extender assembly on the body of the extended-range vehicle, and improving the stability of the body of the extended-range vehicle.

[0023] Optionally, the third suspension further includes a second main board, one end of the second main board is connected to the bushing seat, and the other end of the second main board is provided with a mounting surface, and the mounting surface is connected to the range extender assembly.

[0024] The mounting surface on the second main board is connected and fixed to the range extender assembly, which can increase the connection area between the third mount and the range extender assembly, thereby improving the connection strength between the third mount and the range extender assembly, reducing the shaking between the range extender assembly and the third mount, and improving the structural stability of the range extender vehicle body.

[0025] Optionally, the thickness of the second main board is 4 mm to 5 mm.

[0026] When the second mainboard is 4mm to 5mm thick, it is moderately thick and compact, making it less likely to interfere with other components. Furthermore, the second mainboard has appropriate static and dynamic stiffness, ensuring that it effectively supports and secures the range extender assembly. It is less likely to resonate with the range extender assembly, minimizing impacts on the range extender vehicle's body and cabin. It also reduces the risk of cracks or breakage on the second mainboard, extending its service life. Furthermore, the second mainboard provides excellent vibration isolation, enhancing the third mount's shock and noise reduction performance and improving driving comfort.

[0027] Optionally, the first suspension and the second suspension both include a suspension body, a connecting plate, a first main board and a nut plate, one end of the suspension body is connected to the front cabin assembly, and the other end is connected to the first main board through the connecting plate, and the nut plate is arranged on the first main board and connected to the range extender through bolts.

[0028] The suspension bodies of the first and second mounts are connected to the first mainboard via a connecting plate. This design features a simple structure, stable connection, and facilitates the preparation and processing of various components, making assembly easy and cost-effective. The provision of a nut plate prevents deformation of the first mainboard when the first and second mounts are connected to the range extender assembly, thereby improving its structural stability. Furthermore, the provision of a nut plate prevents excessive thickness of the first mainboard, which would increase preparation costs and reduce vibration isolation effectiveness, thereby improving the vehicle's NVH performance.

[0029] Optionally, the thickness of the first main board is 4 mm to 5 mm; and / or the thickness of the nut plate is 3.5 mm to 4.5 mm; and / or the thickness of the connecting plate is 4 mm to 5 mm.

[0030] When the thickness of the first main board is 4mm to 5mm, and / or the thickness of the nut plate is 3.5mm to 4.5mm, and / or the thickness of the connecting plate is 4mm to 5mm, the thickness of the first main board, nut plate and / or connecting plate is moderate, and the overall structure formed is small in volume and not prone to interference with other components. In addition, the first main board, nut plate and / or connecting plate have appropriate static and dynamic stiffness, which can ensure that the overall structure formed by the first main board, nut plate and connecting plate has a good supporting and fixing effect on the range extender assembly, is not prone to resonance with the range extender assembly, reduces the impact on the body and compartment of the range extender vehicle, and also reduces the risk of cracks or breakage, thereby extending the service life. In addition, the overall structure formed by the first main board, nut plate and connecting plate also has a good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the first suspension and the second suspension, thereby improving driving comfort.

[0031] Optionally, the floor assembly further includes a first floor crossbeam extending in the left-right direction, and at least a portion of the first floor crossbeam is fitted and fixed to the lower side of the central channel, and the third suspension is arranged on the first floor crossbeam.

[0032] The third mount is mounted on the first floor crossmember and connected to the range extender assembly. This allows the first floor crossmember to bear a portion of the range extender assembly's weight. Compared to mounting the third mount directly on the floor itself, this significantly reduces the stress on the floor itself. Furthermore, the first floor crossmember significantly increases the structural strength of the center tunnel. The third mount's direct connection to the first floor crossmember, rather than the center tunnel, improves the installation stability of the range extender assembly. Furthermore, the first floor crossmember cushions vibrations generated by the range extender assembly, thereby enhancing the vehicle's overall shock absorption performance and significantly improving user comfort. For example, the first floor crossmember can increase the structural strength of the center tunnel by 20%, ensuring the structural stability of the floor itself.

[0033] Optionally, the first floor beam includes a first main body portion, a second main body portion, and a raised portion connected between the first main body portion and the second main body portion, wherein the raised portion protrudes upward compared to the first main body portion and the second main body portion, wherein the raised portion is fitly fixed to the lower side surface of the central channel, and the first main body portion and the second main body portion are both fitly fixed to the floor body; the third suspension is arranged on the raised portion.

[0034] The raised portion is fitted and fixed to the lower side of the central channel, and the first main body portion and the second main body portion are both fitted and fixed to the floor body, which can reduce the single-point force on the floor body, reduce the risk of stress concentration on the floor body, and increase the service life of the floor body, thereby increasing the service life of the entire vehicle.

[0035] Optionally, the first body portion and the second body portion each include a first connecting portion and a second connecting portion, and the first connecting portion is connected between the protruding portion and the second connecting portion.

[0036] The first main body portion and the second main body portion both include a first connecting portion and a second connecting portion, so that the first connecting portion, the second connecting portion and the raised portion can be manufactured separately, which facilitates the replacement of the first connecting portion, the second connecting portion or the raised portion, improves the design freedom of the first floor cross member, makes the first floor cross member applicable to different vehicle models, and expands the scope of use of the first floor cross member.

[0037] In addition, the structural strengths of the first connecting portion, the second connecting portion, and the raised portion may be set to be different, so that the assembled first floor beam becomes a variable-strength structure. The structural strength of the first floor beam can be adjusted according to the stress conditions at different positions, thereby reducing the overall weight of the first floor beam and saving costs.

[0038] Optionally, the first connecting portion includes a first bending section and a second bending section that are bent relative to each other, the first bending section is connected to the protruding portion, and the second bending section is connected to the second connecting portion.

[0039] The first connecting portion includes a first bent section and a second bent section that are bent relative to each other, which can increase the connection area between the first connecting portion and the raised portion and the second connecting portion, thereby increasing the connection strength at the connection between the two components and improving the structural stability of the first floor beam.

[0040] Optionally, the strength of the material of the protruding portion is higher than the strength of the material of the first connecting portion and the second connecting portion; or, the thickness of the protruding portion is greater than the thickness of the first connecting portion and the second connecting portion.

[0041] The structural strength of the raised portion is higher than that of the first and second connecting portions, thereby enhancing the supporting effect of the raised portion on the central channel and ensuring the structural stability of the floor assembly. Specifically, when the strength of the material of the raised portion is higher than that of the first and second connecting portions, the structural strength of the raised portion is ensured to be higher than that of the first and second connecting portions, thereby enhancing the supporting effect of the raised portion on the central channel. At the same time, the thickness of the raised portion can be made thinner, thereby reducing the space occupied by the raised portion and improving the space utilization of the central channel. When the thickness of the raised portion is greater than that of the first and second connecting portions, the structural strength of the raised portion can be increased among the raised portion, the first and second connecting portions made of the same material, thereby ensuring the supporting effect of the raised portion on the central channel.

[0042] Optionally, the first floor beams are symmetrically arranged in the left-right direction.

[0043] The first floor cross member is symmetrically arranged in the left-right direction, which can realize the modularization of the first floor cross member, so that the first floor cross member can be moved in the front-to-back direction in the central channel on the floor body, so that the first floor cross member can adapt to different vehicle models, expand the applicability of the first floor cross member, and reduce development costs.

[0044] Optionally, the floor assembly further includes a first floor longitudinal beam and a second floor longitudinal beam, both of which are arranged on the floor body and extend in the front-to-rear direction, and the first floor cross beam is connected to the first floor longitudinal beam and the second floor longitudinal beam at both ends in the length direction.

[0045] The first floor cross member is connected to the first and second floor longitudinal members in the longitudinal direction (left-right direction), providing support for the first floor cross member. Furthermore, the first floor cross member significantly improves the force transmission performance of the floor assembly, allowing the extended-range vehicle to quickly transfer force when subjected to left-right impacts.

[0046] Of course, the first floor crossbeam is connected to the first floor longitudinal beam and the second floor longitudinal beam in the length direction (left-right direction), which can further enhance the structural strength of the floor assembly, thereby improving the installation stability of the range extender assembly.

[0047] When the range extender assembly generates vibration during operation, the first floor crossbeam can disperse the vibration generated by the range extender assembly through the first floor longitudinal beam and the second floor longitudinal beam, thereby reducing the impact of the vibration generated during operation of the range extender assembly on the body of the range extender vehicle and improving user comfort.

[0048] Optionally, the front cabin assembly includes a subframe, the subframe is connected to the first floor longitudinal beam and the second floor longitudinal beam respectively, and the first suspension and the second suspension are arranged on the subframe.

[0049] The first and second floor rails support the subframe. Since the range extender assembly is connected to the subframe via the first and second mounts, and the subframe is connected to the first and second floor rails, the range extender assembly can be indirectly connected to the first and second floor rails via the subframe, making installation of the range extender assembly more flexible.

[0050] When the range extender assembly generates vibration during operation, the subframe can disperse the vibration generated by the range extender assembly through the first floor longitudinal beam and the second floor longitudinal beam, thereby reducing the impact of the vibration generated by the range extender assembly during operation on the body of the extended-range vehicle and improving user comfort.

[0051] Optionally, the front cabin assembly further includes a first front cabin longitudinal beam and a second front cabin longitudinal beam, the first front cabin longitudinal beam extending in the front-to-rear direction, the second front cabin longitudinal beam extending in the front-to-rear direction, and the second front cabin longitudinal beam being spaced apart from the first front cabin longitudinal beam in the left-to-right direction, wherein the subframe is further connected to the first front cabin longitudinal beam and the second front cabin longitudinal beam, respectively.

[0052] As a result, the subframe not only connects the first floor longitudinal beam and the second floor longitudinal beam together, but also connects the first front cabin longitudinal beam and the second front cabin longitudinal beam together, thereby making the connection between the front cabin assembly and the rain floor assembly more stable and improving the installation stability of the range extender assembly.

[0053] The subframe is connected to the first front cabin longitudinal beam and the second front cabin longitudinal beam. When the range extender assembly generates vibration during operation, the subframe can disperse the vibration generated by the range extender assembly through the first front cabin longitudinal beam and the second front cabin longitudinal beam, thereby reducing the impact of the vibration generated during operation of the range extender assembly on the body of the extended-range vehicle and improving user comfort.

[0054] Optionally, the front cabin assembly defines a first accommodating space, the middle channel defines a second accommodating space, the second accommodating space is connected to the first accommodating space, the range extender assembly includes an engine and a generator, the engine and the generator are power-connected, the engine is located in front of the generator, a part of the engine is arranged in the first accommodating space, and the other part of the engine and the generator are arranged in the second accommodating space.

[0055] Part of the range extender assembly is installed in the first storage space defined by the front engine compartment assembly, while the other part is installed in the second storage space defined by the central tunnel. This allows vehicles with smaller front engine compartment assemblies (i.e., vehicles with smaller front ends) to also be equipped with the range extender assembly, thereby making the range extender assembly compatible with a variety of vehicle types, expanding its applicability and improving the internal space utilization of the range-extended vehicle. For example, this structure can shorten the front overhang of the range extender assembly in the front engine compartment assembly by over 170mm, which means that the passenger compartment space can be increased by over 170mm, thus improving the internal space utilization of the range-extended vehicle.

[0056] Part of the engine is arranged in the first accommodation space, and the other part of the engine and the generator are arranged in the second accommodation space. Since the front cabin assembly defines the first accommodation space and the second accommodation space is arranged under the floor assembly, the engine will generate greater noise and vibration when running. Compared with setting the entire engine in the second accommodation space, setting part of the engine in the first accommodation space can obviously greatly reduce the impact of the vibration and noise generated by the engine on passengers, and greatly improve the vehicle's comfort.

[0057] Optionally, the range extender assembly also includes a generator controller, the generator includes a first shell, the motor controller includes a second shell, and the range extender assembly also includes a third shell. The third shell and the first shell together define a first space for accommodating the stator and rotor, and the third shell and the second shell together define a second space for accommodating electrical components. The upper side surface of the first shell is provided with a recessed portion recessed upward, and the first shell is also provided with a plurality of reinforcing ribs, each reinforcing rib is connected to the inner wall surface of the recessed portion and extends in the front-to-back direction.

[0058] The first shell, the second shell and the third shell together define a storage space for the generator and the generator controller. The generator and the generator controller share the third shell, which can greatly reduce the manufacturing cost of the generator and the generator controller and improve the assembly efficiency of the generator and the generator controller.

[0059] The upper side of the first housing features an upwardly concave portion, reinforced with multiple ribs. This increases the vehicle's system modal response and the support strength of the range extender assembly. For example, the vehicle's system modal response can be raised to 316Hz, while the range extender assembly's support strength is increased by 30%, enhancing the vehicle's overall performance.

[0060] Optionally, the range extender assembly includes an engine and a generator, the engine is power-connected to the generator, the engine is located in front of the generator, the engine has a first power output shaft, the generator has a first power input shaft, the first power output shaft is parallel to the second power input shaft and both extend in the front-to-rear direction.

[0061] In other words, the engine and generator are both installed in the front-to-back direction, thereby reducing the space occupied by the left and right directions of the front cabin assembly.

[0062] The first power output shaft can be arranged above the first power input shaft. The first power output shaft and the first power input shaft are parallel and extend in the front-to-rear direction, which can enable the engine power to be transmitted to the generator more smoothly, improve the overall mode of the vehicle system, and reduce the vibration of the range extender assembly.

[0063] The extended-range vehicle body also includes a speed increaser, which includes a first driving gear and a first driven gear that are meshed with each other, the first driving gear is connected to the engine power, and the first driven gear is connected to the generator power, wherein the rotation axis of the first driving gear is spaced apart from the rotation axis of the second driving gear in the upper and lower directions.

[0064] The rotation axis of the first driving gear is spaced apart from the rotation axis of the first driven gear in the up-down direction, which can make full use of the space in the up-down direction of the engine compartment and reduce the space occupied by the speed increaser in the left-right direction of the engine compartment. Of course, it can also make the range extender assembly more compact in the front-to-back direction and significantly reduce the length of the range extender assembly in the front-to-back direction, thereby expanding the scope of application of the range extender assembly and allowing models with smaller front engine compartment assemblies to also be installed with the range extender assembly.

[0065] A second aspect of the present application provides a method for manufacturing a body of an extended-range vehicle, which is used to manufacture the body of the extended-range vehicle described in any of the above embodiments. The method for manufacturing the body of the extended-range vehicle comprises:

[0066] Manufacturing of the front nacelle assembly;

[0067] manufacturing a floor assembly, wherein the floor assembly is provided with a central channel;

[0068] connecting the floor assembly to the front cabin assembly;

[0069] Connecting a first suspension, a second suspension, and a third suspension to the range extender assembly; wherein the first suspension and the second suspension are spaced apart in the left-right direction, and the third suspension is spaced apart from the first suspension and the second suspension in the up-down direction;

[0070] The first suspension and the second suspension are connected to the front cabin assembly, and the third suspension is connected to the central channel.

[0071] Because the first, second, and third mounts together form a triangular structure to secure the range extender assembly, the triangular mount design allows the three mounting points to be evenly spaced around the range extender assembly, forming a stable triangular support structure. This effectively resists various torsional and vibrational forces exerted on the range extender assembly during driving, thereby maintaining the stability and reliability of the range extender assembly and improving the safety and reliability of the vehicle. Furthermore, the triangular mount attenuates vibrations generated by the range extender assembly during operation, reducing their impact on other components of the range extender vehicle, improving vehicle noise levels, and enhancing vehicle comfort. For example, it can reduce noise levels by 3 decibels, enhancing vehicle comfort.

[0072] The third mount is vertically separated from the first and second mounts. This means the first and second mounts can be positioned below the third mount, while the third mount is positioned above them. This means the first and second mounts are positioned below the range extender assembly, while the third mount is positioned above it. This improves vehicle stability and handling, and optimizes the distribution of the range extender assembly's center of mass. Furthermore, the different mount positions optimize vibration isolation in different directions. Positioning the first and second mounts below the range extender assembly mitigates horizontal and vertical vibration, while the third mount is positioned above it, suppressing longitudinal vibration. This layout improves overall vibration isolation, reduces the impact of vibration on the range extender vehicle's body and cab, reduces the likelihood of vehicle failure, and improves operational stability. For example, this can reduce vehicle failure by 20%, improve operational stability, and lower user costs.

[0073] Furthermore, the range extender assembly in the embodiment of the present application can be assembled with the first, second, and third mounts before being integrated with the front cabin assembly and floor assembly. This ensures that the relative positions of the individual mounting points in the free state meet the positional accuracy requirements, reducing the positional tolerance during assembly and ensuring the positional accuracy of the range extender assembly. For example, the positional tolerance can be reduced to within 2 mm to ensure the positional accuracy of the range extender assembly.

[0074] Optionally, manufacturing the floor assembly specifically includes:

[0075] manufacturing floor slabs;

[0076] Performing a drawing process on the floor blank to form the floor body and the central channel, and forming a material storage convex hump on the central channel;

[0077] The floor blank is shaped and the material storage convex bump is pressed downward to form an arc-shaped corner at the connection between the middle channel and the floor body.

[0078] The floor blank is subjected to a drawing process to form a floor body and a central channel, and a material storage bulge is formed on the central channel. When the floor blank after the drawing process is shaped, the material storage bulge can be pressed down to form an arc-shaped corner at the connection between the central channel and the floor body, thereby forming a floor assembly to meet the use requirements of the extended-range vehicle body. This manufacturing process is simple and facilitates the mass production of floor assemblies. Specifically, by forming a material storage bulge on the central channel during the drawing process of the floor blank, a step-like structure can be formed on the side wall of the central channel, thereby ensuring the overall depth of the central channel while avoiding a sharp draft angle, improving the forming conditions, reducing the risk of cracking in the central channel during the drawing process, improving the production yield, and saving manufacturing costs. For example, the production yield of the central channel can be increased to 100%, avoiding cracking in the central channel during the drawing process.

[0079] Optionally, the arc length of the material storage convex hull is equal to the arc length of the corresponding arc corner.

[0080] When the arc length of the material storage bulge is equal to the arc length of the corresponding arc corner, when the material storage bulge is pressed down to form the arc corner at the connection between the central channel and the floor body, the overall thickness of the floor assembly can be made uniform, avoiding the risk of wrinkling, stacking or cracking at the arc corner, further improving the preparation yield and saving manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0081] In order to more clearly illustrate the specific implementation methods of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the specific implementation methods or the description of the prior art. Obviously, the drawings described below are some implementation methods of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0082] Figure 1 A schematic diagram of a partial structure of a range-extended vehicle body in a specific embodiment of the related art;

[0083] Figure 2 A schematic structural diagram of a range-extended vehicle body provided in one embodiment of the present application;

[0084] Figure 3 A schematic structural diagram of a front cabin assembly provided in one embodiment of the present application;

[0085] Figure 4 A schematic structural diagram of a front nacelle assembly provided in an embodiment of the present application but excluding a range extender assembly;

[0086] Figure 5 A bottom view of a front cabin assembly provided in one embodiment of the present application;

[0087] Figure 6 A schematic structural diagram of the front cabin assembly provided in one embodiment of the present application, excluding the range extender assembly and the floor assembly;

[0088] Figure 7 A schematic diagram of a portion of the structure of a range-extended vehicle body provided in one embodiment of the present application;

[0089] Figure 8 A schematic diagram of a partial structure of a range-extended vehicle body provided in one embodiment of the present application from another perspective;

[0090] Figure 9 A side view of a third suspension provided in an embodiment of the present application;

[0091] Figure 10 for Figure 9 A partial enlarged view of

[0092] Figure 11 A schematic diagram of the structure of the third suspension provided in one embodiment of the present application at another angle;

[0093] Figure 12 A schematic structural diagram of a first suspension and a second suspension provided in an embodiment of the present application;

[0094] Figure 13 A schematic diagram of a partial structure of a first suspension provided in one embodiment of the present application;

[0095] Figure 14 A schematic diagram of a partial structure of a second suspension provided in one embodiment of the present application;

[0096] Figure 15 A first suspension and a second suspension are shown;

[0097] Figure 16 A third suspension is shown;

[0098] Figure 17 The mid-channel structure is shown;

[0099] Figure 18 A schematic diagram of a partial structure of a first floor beam provided in one embodiment of the present application;

[0100] Figure 19 A schematic diagram of a portion of the structure of a range-extended vehicle body provided in another embodiment of the present application;

[0101] Figure 20 This is an exploded schematic diagram of a partial structure of a first floor beam provided in one embodiment of the present application;

[0102] Figure 21 A schematic diagram of a partial structure of a floor assembly provided in one embodiment of the present application;

[0103] Figure 22 A schematic structural diagram of a range extender assembly provided in one embodiment of the present application;

[0104] Figure 23 A partially enlarged view of a range extender assembly provided in one embodiment of the present application;

[0105] Figure 24 A partially enlarged view of a range extender assembly provided in one embodiment of the present application;

[0106] Figure 25 A third suspension is shown;

[0107] Figure 26 A flow chart of a method for manufacturing a range-extended vehicle body according to an embodiment of the present application;

[0108] Figure 27 A flow chart of a method for manufacturing a floor assembly provided in one embodiment of the present application;

[0109] Figure 28 The drawing and forming processing state of the floor blank during the manufacturing process of the floor assembly provided in one embodiment of the present application;

[0110] Figure 29 This is the shaping processing state of the floor blank during the manufacturing process of the floor assembly provided in one embodiment of the present application.

[0111] [Description of Reference Numerals]

[0112] Range extender assembly 130'; front suspension 116'; rear suspension 127'; vehicle body 100; front cabin assembly 110; first accommodation space 110A; first suspension 111; second suspension 112; subframe 113; first front cabin longitudinal beam 114; second front cabin longitudinal beam 115; suspension body 116; connecting plate 117; first main board 118; nut plate 119; floor assembly 120; floor body 121; middle channel 122; lower side 1220; second accommodation space 122 A; third suspension 123; bushing seat 1231; elastic member 1232; mounting portion 1232A; connecting arm 1232B; first buffer portion 1232C; second buffer portion 1232D; inner core 1233; first mounting hole 1233A; first arcuate surface 1233B; second arcuate surface 1233C; connecting surface 1233D; first gap 1234; second gap 1235; second main board 1236; mounting surface 1236A; first floor beam 124; first main body 12 4A; second body portion 124B; raised portion 124C; first connecting portion 1241; first bent section 1241A; second bent section 1241B; second connecting portion 1242; first floor longitudinal member 125; second floor longitudinal member 126; third suspension mounting bracket 127; second mounting hole 127A; mounting bolt 128; curved corner 129; range extender assembly 130; engine 131; first power output shaft 131A; generator 132; first power input shaft 132A; Generator controller 133; first housing 140; recessed portion 140A; second housing 141; third housing 142; speed increaser 150; first driving gear 151; first driven gear 152; reinforcing rib 160; battery 170; electric motor 180; fuel tank 190; mounting hole 200; drawing die 301; drawing punch 302; shaping die 401; shaping punch 402; floor slab 500; material storage bump 501; front-to-back direction X; left-to-right direction Y; up-down direction Z. DETAILED DESCRIPTION

[0113] To make the purpose, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without making creative efforts shall fall within the scope of protection of this application.

[0114] Unless otherwise defined, all technical and scientific terms used in the present application have the same meanings as commonly understood by one of ordinary skill in the art to which this application belongs; the terminology used in the specification of the present application is for the purpose of describing particular embodiments only and is not intended to be limiting of the present application; the terms "include" and "have" and any variations thereof, as used in the specification and the claims of the present application, are intended to cover a non-exclusive inclusion; the terms "first", "second", and the like used in the specification and the claims of the present application are used for the purpose of distinguishing between similar objects and are not intended to be defining positions or sequences thereof.

[0115] Reference to "an embodiment" or "the embodiment" in this application means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the application. The appearances of the phrase in various places in the specification are not necessarily all referring to the same embodiment, nor are they necessarily mutually exclusive of one another. It is expressly understood that that the embodiments described in this application are intended to be combined with each other in their various permutations.

[0116] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mount", "connect", "connection", "attach" should be understood in a broad sense, for example, can be fixedly connected, can be detachably connected, or integrally connected; can be directly connected, or indirectly connected through an intermediate medium; can be internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0117] The term "and / or" in the present application is only a description of the association relationship between the associated objects, which means that there can be three relationships, for example, A and / or B can mean that A exists alone, A and B exist together, and B exists alone. In addition, the character " / " in the present application generally represents an "or" relationship between the front and rear associated objects.

[0118] "Multiple" appearing in the present application means two or more (including two), and similarly, "multiple groups" means two or more groups (including two groups), and "multiple pieces" means two or more pieces (including two pieces).

[0119] With the development of new energy vehicles, since the range-extender electric vehicle combines the advantages of pure electric vehicles and fuel vehicles, when the battery power is insufficient, the internal combustion engine will start to charge the battery or directly provide power for the electric motor, thereby greatly extending the cruising range of the electric vehicle, which makes the range-extender vehicle perform well in long-distance travel, reduces the need for frequent charging, and the range-extender vehicle is more and more favored by people. The range-extender assembly includes a generator, an engine, and a generator controller, and the range-extender assembly is usually arranged in the front engine compartment assembly.

[0120] In extended-range vehicles, the range extender assembly is usually supported by multiple suspension devices and installed on the front cabin assembly.

[0121] Figure 1 FIG1 shows a schematic diagram of a partial structure of a range-extended vehicle body in a specific embodiment of the related art. Figure 1 As shown, the front and rear suspensions 116', 127' are both located below the range extender assembly 130'. The range extender assembly 130' is supported by the front and rear suspensions 116', 127', forming a support-down mounting structure. However, due to the large size of the range extender assembly 130' in an extended-range vehicle, the range extender assembly 130' is prone to significant displacement or rotation due to inertia during vehicle operation, resulting in significant vibration amplitude, which can easily affect the vehicle body and cab.

[0122] In view of this, the present application provides a range-extended vehicle body and a manufacturing method thereof, which reduces the vibration amplitude of the range-extender assembly during driving, reduces the impact of the range-extender assembly vibration on the range-extended vehicle body and cab, and improves the noise level of the range-extended vehicle body. The vehicles disclosed in the embodiments of the present application can include miniature vehicles with short range-extended vehicle bodies and a small number of seats (two or four seats), as well as small cars, compact cars, mid-sized cars, mid-to-large cars, and other models.

[0123] The front cabin assembly disclosed in the embodiment of the present application may include a first accommodating space, a first suspension, a second suspension, a subframe, a first front cabin longitudinal beam, and a second front cabin longitudinal beam.

[0124] The floor assembly disclosed in the embodiment of the present application may include a floor body, a central channel, a second accommodating space, a third suspension, a first floor cross beam, a first floor longitudinal beam, and a second floor longitudinal beam.

[0125] For the convenience of description, the following embodiments are described by taking a range-extended vehicle body according to an embodiment of the present application as an example.

[0126] Please refer to Figures 2 to 8 , Figure 2 A schematic structural diagram of a range-extended vehicle body provided in one embodiment of the present application; Figure 3 A schematic structural diagram of a front cabin assembly 110 provided in one embodiment of the present application; Figure 4 This is a structural diagram of the front nacelle assembly 110 provided in one embodiment of the present application but excluding the range extender assembly 130; Figure 5 A bottom view of the front nacelle assembly 110 provided in one embodiment of the present application;

[0127] Figure 6A schematic structural diagram of the front cabin assembly 110 provided in one embodiment of the present application, excluding the range extender assembly 130 and the floor assembly 120; Figure 7 A side view of the range extender assembly 130 and the first mount 111 , the second mount 112 , and the third mount 123 is shown; Figure 8 A schematic structural diagram of the range extender assembly 130 , the first mount 111 , the second mount 112 , and the third mount 123 is shown.

[0128] like Figures 2 to 8 As shown, the present application provides a range-extended vehicle body 100 , which can be applied to multiple vehicle models such as the New Rongguang series.

[0129] The vehicle comprises a front cabin assembly 110, a floor assembly 120, and a range extender assembly 130. The front cabin assembly 110 is provided with a first suspension 111 and a second suspension 112, which are spaced apart in the left-right direction Y. The floor assembly 120 is located behind the front cabin assembly 110. The floor assembly 120 comprises a floor body 121 and a central channel 122 disposed therein. A third suspension 123 is disposed on the central channel 122. The third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the front-to-back direction X, respectively. The third suspension 123 is also spaced apart from the first suspension 111 and the second suspension 112 in the vertical direction Z, respectively. The range extender assembly 130 is secured to the front cabin assembly 110 and the floor assembly 120 via the first suspension 111, the second suspension 112, and the third suspension 123.

[0130] A first suspension 111 and a second suspension 112 are provided on the front cabin assembly 110, and a third suspension 123 is provided on the middle channel 122. The first suspension 111 and the second suspension 112 are arranged in the first accommodating space 110A, and the third suspension 123 is arranged in the second accommodating space 122A. The first suspension 111 and the second suspension 112 are arranged in front of the third suspension 123, and the third suspension 123 is arranged behind the first suspension 111 and the second suspension 112. The first suspension 111 and the second suspension 112 are spaced apart in the front-to-back direction X. The first suspension 111, the second suspension 112 and the third suspension 123 together form a triangular structure. The range extender assembly 130 is fixed to the front cabin assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0131] Because the first, second, and third mounts 111, 112, and 123 together form a triangular structure to secure the range extender assembly 130, the triangular mount design allows the three mounting points to be evenly distributed around the range extender assembly 130, forming a stable triangular support structure. This effectively resists various torsional and vibrational forces exerted on the range extender assembly 130 during vehicle operation, thereby maintaining the operational stability and reliability of the range extender assembly 130 and improving the safety and reliability of the vehicle. Furthermore, the triangular mount attenuates vibrations generated by the range extender assembly 130 during operation, reducing their impact on other components of the range extender vehicle body 100, thereby improving vehicle noise and enhancing vehicle comfort. For example, this can reduce vehicle noise by 3 decibels, enhancing vehicle comfort.

[0132] The range extender assembly 130 is secured to the front cabin assembly 110 and the floor assembly 120 via a triangular mount, allowing for independent installation and removal of the range extender assembly 130. This facilitates repair and replacement of the range extender assembly 130 in the event of a malfunction, thereby improving vehicle manufacturing and assembly efficiency. Furthermore, the triangular mount layout is compact, maximizing space within the range-extended vehicle body 100, minimizing interference with other components, and improving overall vehicle space utilization.

[0133] The range extender assembly 130 is fixed to the front cabin assembly 110 and the floor assembly 120 through a triangular suspension, which is also beneficial to reduce power loss during transmission, improve the power output efficiency of the range extender assembly 130, and further enhance the overall performance of the vehicle.

[0134] The third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z, respectively. That is, the first suspension 111 and the second suspension 112 may be below the third suspension 123, and the third suspension 123 is above the first suspension 111 and the second suspension 112. That is, the first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, thereby improving the stability and controllability of the vehicle and making the center of mass distribution of the range extender assembly 130 more reasonable. Furthermore, different mount positions can optimize vibration isolation in different directions. The first and second mounts 111, 112 are positioned below the range extender assembly 130, facilitating horizontal and vertical vibration suppression. The third mount 123 is positioned above the range extender assembly 130, suppressing longitudinal vibration. This layout improves vibration isolation, reduces the impact of vibration on the range-extended vehicle body and cab, lowers the probability of vehicle failure, and improves operational stability. For example, it can reduce the probability of vehicle failure by 20%, improve operational stability, and lower user costs.

[0135] Furthermore, the range extender assembly 130 in the embodiment of the present application can be assembled with the first mount 111, the second mount 112, and the third mount 123, and then integrated with the front cabin assembly 110 and the floor assembly 120. This ensures that the relative positions of the three mounting points in the free state meet the positional accuracy requirements, reduces the positional tolerance during the assembly process, and ensures the positional accuracy of the range extender assembly 130. For example, the positional tolerance can be reduced to within 2 mm to ensure the positional accuracy of the range extender assembly.

[0136] In a specific embodiment, the displacement of the range extender assembly 130 in the front-to-back direction X is generally required to be between -15 mm and 15 mm, and the rotation angle in the left-to-right direction Y is generally required to be between -1.5° and 1.5°. Figure 1In the related art shown, when the vehicle has an acceleration between -11g and 11g, during a frontal or rear collision, the maximum positive displacement of the range extender assembly 130' is 15.677mm, the maximum negative displacement is -16.958mm, the maximum positive rotation angle of the range extender assembly 130' is 1.675°, and the maximum negative rotation angle is -1.9°; when the vehicle has an acceleration between -3g and 3g, during a forward or reverse collision, the maximum positive displacement of the range extender assembly 130' is 12.808mm, the maximum negative displacement is -13.396mm, the maximum positive rotation angle of the range extender assembly 130' is 1.376°, and the maximum negative rotation angle is -1.452°. Among them, when the vehicle acceleration is between -11g and 11g, the maximum positive displacement and maximum negative displacement of the range extender assembly 130' both exceed the required range of -15mm to 15mm, and the maximum positive rotation angle and maximum negative rotation angle of the range extender assembly 130' both exceed the required range of -1.5° to 1.5°. The large displacement causes a large vibration amplitude, which can easily affect the body and cab of the range-extended vehicle and cause a lot of noise.

[0137] When the vehicle provided in the embodiment of the present application has an acceleration between -11g and 11g, during a front or rear collision, the maximum positive displacement of the range extender assembly 130 is 14.8mm, the maximum negative displacement is -13.4mm, the maximum positive rotation angle of the range extender assembly 130 is 1.48°, and the maximum negative rotation angle is -1.15°; when the vehicle provided in the embodiment of the present application has an acceleration between -3g and 3g, during a forward or backward collision, the maximum positive displacement of the range extender assembly 130 is 9.9mm, the maximum negative displacement is -9.2mm, the maximum positive rotation angle of the range extender assembly 130 is 0.89°, and the maximum negative rotation angle is -0.69°. As can be seen, the vehicle provided by the embodiment of the present application effectively reduces the displacement of the range extender assembly 130 in the front-to-back direction X and the rotation angle in the left-to-right direction Y. That is, under the above conditions, the maximum displacement during front collision, rear collision, forward movement, and reverse movement is between -15mm and 15mm, and the maximum rotation angle is between -1.5° and 1.5°. This can reduce the vibration amplitude of the range extender assembly 130 and the impact of the vibration generated by the range extender assembly 130 on other parts of the range-extended vehicle body, thereby improving the vehicle's user comfort and reducing the noise level of the range-extended vehicle body. For example, the noise level of the range-extended vehicle body can be reduced by 3 decibels, improving the user comfort of the vehicle.

[0138] In some embodiments, the first suspension 111 and the second suspension 112 are arranged below the engine 131, and the third suspension 123 is arranged above the generator 132 or the generator controller 133. Since the weight, volume and vibration generated during operation of the engine 131 are usually higher than the generator 132, the first suspension 111 and the second suspension 112 are arranged below the engine 131, which can increase the support points of the engine 131, thereby greatly improving the stability and reliability of the operation of the engine 131.

[0139] In some embodiments, the first suspension 111, the second suspension 112 and the third suspension 123 can be set as rubber suspension, hydraulic suspension, semi-active suspension and active suspension. The rubber suspension is made of natural rubber or synthetic rubber and has excellent physical and mechanical properties, sound insulation, vibration isolation and buffering capabilities. The rubber suspension can be divided into bushing-type suspension, square-shaped rubber suspension and wedge-shaped rubber suspension according to its structure; the hydraulic suspension is internally arranged with a decoupling disc / membrane and a flow channel plate forming an inertial channel to absorb and attenuate vibrations through the flow of liquid. The hydraulic suspension is divided into cylindrical hydraulic suspension and trapezoidal hydraulic suspension according to its structure. The pressure mount has excellent dynamic characteristics and can adapt to the vibration and noise reduction needs under different frequencies and amplitudes; the semi-active mount combines an electronic control unit, a solenoid valve and a mount body with a movable valve (which can be a rubber mount or a hydraulic mount), and dynamically adjusts the stiffness and damping of the mount by controlling the flow of liquid to adapt to different working conditions; the active mount generates dynamic force through the actuator to offset the vibration of the engine to achieve more precise vibration control. The active mount consists of a passive mount (rubber mount or hydraulic mount), a vibration sensor, a controller and an actuator, which can effectively suppress high-frequency vibration and noise.

[0140] Figure 9 A side view of the third suspension is shown.

[0141] like Figure 7 Of Figure 9 As shown, in one specific embodiment, the third suspension 123 includes a bushing seat 1231, an elastic member 1232, and an inner core 1233. The elastic member 1232 is mounted within the bushing seat 1231, and the inner core 1233 is mounted within the elastic member 1232. The inner core 1233 is provided with a first mounting hole 1233A. A third suspension mounting bracket 127 is provided on the central channel 122, and the third suspension mounting bracket 127 is provided with a second mounting hole 127A. The second mounting hole 127A is connected to the first mounting hole 1233A via a mounting bolt 128.

[0142] In this embodiment, a first mounting hole 1233A on the inner core 1233 of the third suspension 123 is connected to a second mounting hole 127A on the third suspension mounting bracket 127 via a mounting bolt 128. This connection is strong, simple, and easy to implement. An elastic member 1232 disposed between the bushing seat 1231 and the inner core 1233 can adaptively reduce vibration of the range extender assembly 130 during operation, thereby providing a good buffering effect during vibration of the range extender assembly 130, reducing the impact of vibration of the range extender assembly 130 on the body of the range extender vehicle, improving the stability of the range extender vehicle, and preventing collision between the inner core 1233 and the bushing seat 1231 during operation of the range extender assembly 130, thereby reducing noise.

[0143] In a specific embodiment, Figure 8 and Figure 9 As shown, the center position of the first mounting hole 1233A is lower than the center position of the second mounting hole 127A in the up-down direction.

[0144] In this embodiment, after the range extender assembly 130 is assembled, the weight of the range extender assembly 130 itself can be used to pull the third suspension 123 downward, so that the mounting bolt 128 fits the inner wall surface of the first mounting hole 1233A, thereby improving structural stability, and can drive the third suspension 123 to a more precise installation position, thereby improving the installation accuracy of the third suspension 123 and avoiding positional interference between the third suspension 123 and other components.

[0145] In some embodiments, the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A in the up and down direction Z can be between 0.5 mm and 1.5 mm, for example, it can be 0.5 mm, 0.8 mm, 1 mm, 1.2 mm, 1.5 mm, etc., to avoid the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A being too large, causing the mounting bolt 128 to be unable to match the installation, or the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A being too small, which cannot improve the installation accuracy of the third suspension 123.

[0146] Furthermore, if Figure 8 and Figure 9 As shown, the diameter of the first mounting hole 1233A is larger than the diameter of the mounting bolt 128 .

[0147] In this embodiment, the diameter of the first mounting hole 1233A is greater than the diameter of the mounting bolt 128, so that the mounting bolt 128 has a certain displacement in the up-down direction Z in the first mounting hole 1233A, so that after the subsequent range extender assembly 130 is assembled, the third suspension 123 can be pulled down by the weight of the range extender assembly 130 itself, so that the mounting bolt 128 is attached to the inner wall surface of the first mounting hole 1233A. In addition, the diameter of the first mounting hole 1233A is greater than the diameter of the mounting bolt 128, which facilitates the matching installation of the mounting bolt 128, reduces the installation difficulty of the mounting bolt 128, and avoids improving the installation convenience.

[0148] Exemplarily, the diameter of the first mounting hole 1233A can be 13 mm, and the diameter of the mounting bolt 128 can be 12 mm, so as to facilitate the matching installation of the mounting bolt 128 and the first mounting hole 1233A. Of course, the diameters of the first mounting hole 1233A and the mounting bolt 128 can also be other values, which can be set according to actual needs, and are not limited herein.

[0149] In a specific embodiment, as shown in Figure 8 and 9 , the elastic member 1232 includes a mounting portion 1232A and a connecting arm 1232B, one end of the connecting arm 1232B is connected with the inner wall of the bushing seat 1231, and the other end of the connecting arm 1232B is connected with the mounting portion 1232A; the mounting portion 1232A includes a mounting cavity, and the inner core 1233 is installed in the mounting cavity.

[0150] In this embodiment, the inner core 1233 is arranged in the mounting cavity of the mounting portion 1232A, which can improve the connection stability of the inner core 1233 and the elastic member 1232. After the range extender assembly 130 is assembled, the inner core 1233 is displaced by the vibration of the range extender assembly 130, and the connecting arm 1232B connected with the bushing seat 1231 and the mounting portion 1232A can provide the inner core 1233 with reverse tension and buffering force, which can adaptively reduce the jitter of the range extender assembly 130 during the operation of the range extender assembly 130, and avoid the vibration amplitude of the inner core 1233 and the range extender assembly 130 being too large, so as to play a good buffering effect during the vibration of the range extender assembly 130.

[0151] Further, as shown in Figure 10 , Figure 10 , a partial enlarged view of Figure 9 is shown, Figure 10The inner core 1233 includes a first curved surface 1233B, a second curved surface 1233C, and a connecting surface 1233D connecting the first curved surface 1233B and the second curved surface 1233C. The diameter of the first curved surface 1233B is larger than the diameter of the second curved surface 1233C. The connecting arm 1232B connects to the corresponding positions of the second curved surface 1233C and the connecting surface 1233D on the mounting portion 1232A.

[0152] In this embodiment, the diameter of first curved surface 1233B is larger, thereby providing inner core 1233 with sufficient volume to accommodate the corresponding positioning holes and mounting holes. This improves the overall strength of inner core 1233, prevents damage to inner core 1233, and enhances the structural stability of third suspension 123. Furthermore, the diameter of second curved surface 1233C is smaller than that of first curved surface 1233B, and connecting arm 1232B is connected to corresponding locations of second curved surface 1233C and connecting surface 1233D on mounting portion 1232A. This increases the volume of connecting arm 1232B, thereby enhancing the cushioning effect of connecting arm 1232B and the connection area between connecting arm 1232B and corresponding locations of inner core 1233 on mounting portion 1232A. This prevents excessive stress concentration from inner core 1233 on connecting arm 1232B, improves the fatigue durability of connecting arm 1232B, and extends the service life of elastic member 1232.

[0153] The number of connecting arms 1232B can be two, symmetrically arranged on opposite sides of the mounting portion 1232A and the inner core 1233, to prevent excessive stress concentration on the connecting arms 1232B from the inner core 1233, thereby improving the fatigue durability of the connecting arms 1232B. Of course, the number of connecting arms 1232B can also be two, three, four, etc., to increase design flexibility. The specific number can be set according to actual needs and is not limited here.

[0154] In a specific embodiment, Figure 9 As shown, the elastic member 1232 further includes a first buffer portion 1232C and a second buffer portion 1232D. A first gap 1234 is formed between the first buffer portion 1232C and the connecting arm 1232B and the mounting portion 1232A. A second gap 1235 is formed between the second buffer portion 1232D and the connecting arm 1232B and the mounting portion 1232A. The first gap 1234 and the second gap 1235 are spaced apart in the vertical direction Z.

[0155] In this embodiment, the setting of the first gap 1234 and the second gap 1235 can provide a buffer space for the inner core 1233 to move with the vibration of the range extender assembly 130, further reducing the force transmitted by the inner core 1233 to the first buffer part 1232C and the second buffer part 1232D, thereby improving the buffering effect, reducing the impact of the vibration of the range extender assembly 130 on the body of the extended-range vehicle, and improving the stability of the body of the extended-range vehicle.

[0156] Figure 11 FIG. 1 shows a schematic diagram of the structure of the third suspension 123 at another angle. Figure 8 As shown, the third suspension 123 further includes a second main board 1236 , one end of the second main board 1236 is connected to the bushing seat 1231 , and the other end of the second main board 1236 is provided with a mounting surface 1236A, which is connected to the range extender assembly 130 .

[0157] In this embodiment, Figure 8 and Figure 11 As shown, the mounting surface 1236A on the second main board 1236 is connected and fixed to the range extender assembly 130, which can increase the connection area between the third suspension 123 and the range extender assembly 130, thereby improving the connection strength between the third suspension 123 and the range extender assembly 130, reducing the shaking between the range extender assembly 130 and the third suspension 123, and improving the structural stability of the vehicle.

[0158] The mounting surfaces 1236A can be symmetrically arranged on the second mainboard 1236 to increase the contact area between the mounting surface 1236A and the range extender assembly 130, thereby improving the connection strength. In other embodiments, the second mainboards 1236 can be symmetrically arranged on opposite sides of the bushing seat 1231 to increase the design freedom of the third mount 123 and enable the third mount 123 to adapt to different vehicle body structures.

[0159] In addition, the size of the third suspension 123 can be changed with the size and position of the range extender assembly 130, and can be set according to actual needs so that the third suspension 123 can adapt to the extended-range vehicle body structure of different vehicles, which is not limited here.

[0160] In a specific embodiment, Figure 11 As shown, the thickness of the second main board 1236 is 4 mm to 5 mm. For example, the thickness of the second main board 1236 can be 4 mm, 4.2 mm, 4.5 mm, 4.7 mm, 5 mm, etc. The thickness can be set according to actual needs and is not limited here.

[0161] If the thickness of the second main plate 1236 is too thin, for example, less than 4 mm, the static stiffness and dynamic stiffness of the second main plate 1236 are both low, and the second main plate 1236 is prone to bending and torsion, which reduces the supporting and fixing effect of the third suspension 123 on the range extender assembly 130 and is prone to vibration noise. The second main plate 1236 is also prone to resonance with the range extender assembly 130, which can cause the second main plate 1236 to crack or break, reduce the service life, and also affect the range extended vehicle body and the vehicle cabin, reducing the comfort of driving and riding. If the thickness of the second main plate 1236 is too thick, for example, greater than 5 mm, the static stiffness and dynamic stiffness of the second main plate 1236 are both too high, which can reduce the isolation effect of the second main plate 1236 on high-frequency vibration of the range extender assembly 130. In addition, the thickness of the second main plate 1236 is too thick, which can increase the volume of the second main plate 1236, interfere with other components in the range extended vehicle body 100, and also increase the overall weight and manufacturing cost of the third suspension 123, which is not conducive to the lightweight design of the vehicle.

[0162] Therefore, when the thickness of the second main plate 1236 is 4 mm to 5 mm, the thickness of the second main plate 1236 is moderate, and the volume is small, which is not prone to interference with other components. In addition, the second main plate 1236 has appropriate static stiffness and dynamic stiffness, which can ensure that the second main plate 1236 has a good supporting and fixing effect on the range extender assembly 130, is not prone to resonance with the range extender assembly 130, reduces the impact on the range extended vehicle body and the vehicle cabin, and also reduces the risk of cracking or breaking of the second main plate 1236, prolonging the service life. In addition, the second main plate 1236 also has a good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the third suspension 123, and improve the comfort of driving and riding.

[0163] Figure 12 The structure of the first suspension and the second suspension is shown. As shown in Figure 12 In one embodiment, the first suspension 111 and the second suspension 112 each include a suspension body 116, a connecting plate 117, a first main plate 118, and a nut plate 119. One end of the suspension body 116 is connected to the front engine compartment assembly 110, and the other end is connected to the first main plate 118 through the connecting plate 117. The nut plate 119 is arranged on the first main plate 118 and connected to the range extender assembly 130 through bolts.

[0164] In this embodiment, the suspension bodies 116 of the first and second mounts 111, 112 are connected to the first mainboard 118 via a connecting plate 117. This provides a simple structure, a stable connection, and facilitates the preparation and processing of various components, making assembly easy and cost-effective. The provision of a nut plate 119 prevents deformation of the first mainboard 118 when the first and second mounts 111, 112 are connected to the range extender assembly 130, thereby improving the structural stability of the first mainboard 118. Furthermore, the provision of the nut plate 119 prevents excessive thickness of the first mainboard 118, which would increase preparation costs and reduce vibration isolation effectiveness, thereby improving the vehicle's NVH performance.

[0165] The suspension body 116 can be connected to the connecting plate 117 by bolts or welding, and the connecting plate 117 can be connected to the first main board 118 by welding, etc., to improve the connection stability between the suspension body 11, the connecting plate 117, and the first main board 118. The nut plate 119 can be formed on the surface of the first main board 118 by welding or integral molding, thereby improving the structural stability of the first suspension 111 and the second suspension 112.

[0166] In addition, the formation of the first main board 118 of the first suspension 111 and the second suspension 112 can be designed differently, and the number and position of the nut plates 119 on the first main board 118 can also be different. It can be specifically set according to the installation requirements of the range extender assembly 130 and the first suspension 111 and the second suspension 112, and is not limited here.

[0167] Figure 13 shows a partial structural diagram of the first suspension, Figure 14 FIG. 1 shows a partial structural diagram of the second suspension. Figure 13 and Figure 14 As shown, in a specific embodiment, the thickness of the first main board 118 is 4mm to 5mm, and / or the thickness of the nut plate 119 is 3.5mm to 4.5mm, and / or the thickness of the connecting plate 117 is 4mm to 5mm. For example, the thickness of the first main board 118 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc., the thickness of the nut plate 119 can be 3.5mm, 3.7mm, 4mm, 4.2mm, 4.5mm, etc., and the thickness of the connecting plate 117 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc. The specific settings can be made according to actual needs and are not limited here.

[0168] If the first mainboard 118, nut plate 119, and / or connecting plate 117 are too thin, their static and dynamic stiffness are low, and they are prone to bending and torsion, which reduces the support and fixing effect of the first and second mounts 111, 112 on the range extender assembly 130 and is also prone to vibration and abnormal noise. If the first mainboard 118, nut plate 119, and / or connecting plate 117 are too thin, they are prone to resonance with the range extender assembly 130, reducing the risk of cracking or breaking components and shortening their service life. They are also likely to affect the body and cabin of the range extender vehicle, reducing driving comfort. If the first mainboard 118, nut plate 119, and / or connecting plate 117 are too thick, their static and dynamic stiffness are too high, which is likely to reduce the isolation effect of the high-frequency vibration of the range extender assembly 130. Moreover, excessive thickness may increase the volume of components, easily interfere with other components in the extended-range vehicle body 100, and increase the overall weight and manufacturing cost of the first suspension 111 and the second suspension 112, which is not conducive to the lightweight design of the vehicle.

[0169] Therefore, when the thickness of the first main board 118 is 4 mm to 5 mm, and / or the thickness of the nut plate 119 is 3.5 mm to 4.5 mm, and / or the thickness of the connecting plate 117 is 4 mm to 5 mm, the thickness of the first main board 118, nut plate 119, and / or connecting plate 117 is moderate, resulting in a relatively small overall structure that is less likely to interfere with other components. Furthermore, the first main board 118, nut plate 119, and / or connecting plate 117 have appropriate static and dynamic stiffness, ensuring that the overall structure formed by the first main board 118, nut plate 119, and connecting plate 117 provides good support and fixation for the range extender assembly 130, is less likely to resonate with the range extender assembly 130, and reduces the impact on the body and compartment of the range extender vehicle. Furthermore, the risk of cracks or breakage is reduced, thereby extending the service life. In addition, the overall structure formed by the first main board 118, the nut plate 119 and the connecting plate 117 also has a good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the first suspension 111 and the second suspension 112, and improve the driving comfort.

[0170] In one specific embodiment, when the maximum engine speed N in the range extender assembly 130 is 6000 RPM, the engine's second-order natural frequency f2 = N / 60*2 = 200 Hz and its fourth-order natural frequency f4 = N / 60*4 = 400 Hz can be calculated. Based on the vehicle's noise, vibration, and harshness (NVH) performance requirements, the first-order modal natural frequency F of the mount is typically required to be ≥ 500 Hz. In the embodiment of the present application, the thickness of the first main board 118 of the first suspension 111 is 4.5 mm, the thickness of the three nut plates 119 is 4 mm, the thickness of the connecting plate 117 is 4.5 mm, and the first-order modal natural frequency of the overall structure formed by the first main board 118, the nut plate 119 and the connecting plate 117 is 633 Hz; the thickness of the first main board 118 of the second suspension 112 is 4.5 mm, the thickness of the three nut plates 119 is 4 mm, the thickness of the connecting plate 117 is 4.5 mm, the first main board 118, the nut plate 119 and the connecting plate 117 are 633 Hz. The first-order modal natural frequency of the overall structure formed by the plate 117 is 572 Hz; the thickness of the second main board 1236 of the third suspension 123 is 4.5 mm, and its first-order modal natural frequency is 594 Hz. In this application, the first suspension 111, the second suspension 112 and the third suspension 123 can all meet the NVH performance requirements of the vehicle, avoiding resonance with the range extender assembly 130, improving the NVH performance of the vehicle, and reducing the risk of cracks or fracture failure of the first suspension 111, the second suspension 112 and the third suspension 123.

[0171] Figure 15 A first suspension 111 and a second suspension 112 are shown; Figure 16 A third suspension 123 is shown; Figure 17 Shown Figure 8 The center channel 122 structure is shown.

[0172] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 8 、 Figure 15 、 Figure 16 and Figure 17 As shown, in this embodiment, the floor assembly 120 further includes a first floor cross member 124 extending along the left-right direction Y, and at least a portion of the first floor cross member 124 is affixed to the lower side surface 1220 of the central channel 122 , and the third suspension 123 is disposed on the first floor cross member 124 .

[0173] The first floor cross member 124 extends in the left-right direction Y, and at least a portion of the first floor cross member 124 is fixedly attached to the lower side surface 1220 of the central channel 122. That is, at least a portion of the first floor cross member 124 is attached to the floor body 121. The first floor cross member 124 can partially support the floor body 121. Since the floor body 121 is subjected to relatively large forces, the first floor cross member 124 supports the floor body 121, effectively sharing the forces of the floor body 121, avoiding a single-point force situation on the floor body 121, and improving the service life and efficiency of the floor body 121.

[0174] The third mount 123 is mounted on the first floor cross member 124 and connected to the range extender assembly 130. This allows the first floor cross member 124 to bear a portion of the weight of the range extender assembly 130. Compared to mounting the third mount 123 directly on the floor body 121, placing the third mount 123 on the first floor cross member 124 significantly reduces the stress on the floor body 121. Furthermore, the first floor cross member 124 significantly increases the structural strength of the center tunnel 122. The direct connection of the third mount 123 to the first floor cross member 124, rather than to the center tunnel 122, improves the installation stability of the range extender assembly 130. Furthermore, the first floor cross member 124 buffers vibrations generated by the range extender assembly 130, thereby enhancing the overall shock absorption performance of the vehicle and significantly improving user comfort. For example, the first floor cross member 124 can increase the structural strength of the center tunnel 122 by 20%, ensuring the structural stability of the floor body 121.

[0175] In some embodiments, the first floor cross member 124 can be made of a relatively high-strength material. For example, the first floor cross member 124 can be made of steel or aluminum alloy. Steel has high strength and rigidity, providing a stable support structure for the EREV body. This high strength and rigidity ensures that the first floor cross member 124 does not deform when subjected to various loads. Furthermore, because steel is easily shaped and welded during processing, this ensures a secure connection between the first floor cross member 124 and other components of the EREV body 100. Steel also has excellent durability and fatigue resistance, ensuring that the first floor cross member 124 maintains stable performance over long-term use. Aluminum alloy has excellent lightweight properties and high rigidity. Compared to steel, using aluminum alloy for the first floor cross member 124 can significantly reduce the weight of the EREV body, thereby improving the vehicle's fuel economy and reducing its environmental impact. Furthermore, aluminum alloy has excellent corrosion resistance, ensuring a long service life in harsh environments.

[0176] In some embodiments, the first floor beam 124 and the third suspension 123 can be connected by bolts. Bolted connections are a detachable connection method. When the equipment needs to be repaired, replaced, or adjusted, they can be easily separated by removing the bolts without damaging the connecting parts. Furthermore, the bolts themselves are made of high-strength materials such as carbon steel, stainless steel, or alloy steel, capable of withstanding significant tensile and shear forces. Furthermore, by selecting the appropriate bolt diameter, length, and thread type, their load-bearing capacity and durability can be further enhanced, ensuring the long-term stability of the connection. Bolted connections offer a high degree of precision because the tightness and stability of the connection can be ensured by controlling the tightening torque and preload of the bolts. This precision helps reduce loosening and vibration, improving the operating efficiency and reliability of the equipment. Bolted connections generally do not require complex installation tools or equipment; installation can be completed using basic tools such as wrenches and screwdrivers. Furthermore, the detachable nature of the bolts makes equipment maintenance and upkeep easier and more convenient.

[0177] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17 As shown, in this embodiment, the floor assembly 120 further includes a first floor longitudinal beam 125 and a second floor longitudinal beam 126. The first floor longitudinal beam 125 and the second floor longitudinal beam 126 are both disposed on the floor body 121 and extend in the front-to-rear direction X. The first floor cross member 124 is connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126 at both ends in the longitudinal direction.

[0178] The first floor stringer 125 and the second floor stringer 126 are spaced apart in the left-right direction Y. The first floor stringer 125 and the second floor stringer 126 are both disposed on the floor body 121 and extend in the front-back direction X. The first floor stringer 125 and the second floor stringer 126 provide a certain degree of support for the floor body 121, thereby reducing single-point stress on the floor body 121 and lowering the risk of stress concentration on the floor body 121.

[0179] The first floor cross member 124 is connected to the first floor longitudinal member 125 and the second floor longitudinal member 126 in the longitudinal direction (left-right direction Y). The first floor longitudinal member 125 and the second floor longitudinal member 126 provide support for the first floor cross member 124. Furthermore, the first floor cross member 124 significantly improves the force transmission performance of the floor assembly 120, allowing the vehicle to quickly transfer force when subjected to force in the left-right direction Y.

[0180] Of course, the first floor cross member 124 is connected to the first floor longitudinal member 125 and the second floor longitudinal member 126 in the length direction (left-right direction Y), which can further enhance the structural strength of the floor assembly 120 , thereby improving the installation stability of the range extender assembly 130 .

[0181] Since the range extender assembly 130 is connected to the first floor cross member 124 via the third suspension 123, and the first floor cross member 124 is connected to the first floor longitudinal member 125 and the second floor longitudinal member 126, when the range extender assembly 130 generates vibration during operation, the first floor cross member 124 can disperse the vibration generated by the range extender assembly 130 through the first floor longitudinal member 125 and the second floor longitudinal member 126, thereby reducing the impact of the vibration generated during operation of the range extender assembly on the vehicle and improving user comfort.

[0182] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17 In this embodiment, the front cabin assembly 110 includes a subframe 113 , which is connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126 , respectively. The first suspension 111 and the second suspension 112 are provided on the subframe 113 .

[0183] Front cabin assembly 110 includes a subframe 113, which is positioned at the front of the range-extended vehicle body. Subframe 113 is connected to first and second floor rails 125, 126. First and second mounts 111, 112 are mounted on subframe 113 and connected to first and second floor rails 125, 126 in the longitudinal direction (left-right direction Y). These first and second floor rails 125, 126 support subframe 113. Because range extender assembly 130 is connected to subframe 113 via first and second mounts 111, 112, respectively, and subframe 113 is connected to first and second floor rails 125, 126, range extender assembly 130 can be indirectly connected to first and second floor rails 125, 126 via subframe 113, making installation of range extender assembly 130 more flexible.

[0184] When the range extender assembly 130 generates vibration during operation, the subframe 113 can disperse the vibration generated by the range extender assembly 130 through the first floor longitudinal beam 125 and the second floor longitudinal beam 126, thereby reducing the impact of the vibration generated by the range extender assembly 130 during operation on the vehicle and improving user comfort.

[0185] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17 As shown, in this embodiment, the front cabin assembly 110 further includes a first front cabin longitudinal beam 114 and a second front cabin longitudinal beam 115. The first front cabin longitudinal beam 114 extends along the front-to-back direction X, the second front cabin longitudinal beam 115 extends along the front-to-back direction X, and the second front cabin longitudinal beam 115 is spaced apart from the first front cabin longitudinal beam 114 in the left-to-right direction Y. The subframe 113 is also connected to the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115, respectively.

[0186] Thus, the subframe 113 not only connects the first floor longitudinal beam 125 and the second floor longitudinal beam 126 together, but also connects the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115 together, thereby making the connection between the front cabin assembly 110 and the floor assembly 120 more stable and improving the installation stability of the range extender assembly 130.

[0187] The subframe 113 is connected to the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115. The first suspension 111 and the second suspension 112 are arranged on the subframe 113. The subframe 113 is connected to the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115 in the length direction (left and right direction Y). The first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115 can support the subframe 113. Since the range extender assembly 130 is connected to the subframe 113 through the first suspension 111 and the second suspension 112 respectively, and the subframe 113 is connected to the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115, when the range extender assembly 130 generates vibration during operation, the subframe 113 can disperse the vibration generated by the range extender assembly 130 through the first front cabin longitudinal beam 114 and the second front cabin longitudinal beam 115, thereby reducing the impact of the vibration generated by the range extender assembly 130 during operation on the vehicle and improving the user's comfort.

[0188] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17As shown, in this embodiment, the first floor beam 124 includes a first main body portion 124A, a second main body portion 124B and a raised portion 124C connected between the first main body portion 124A and the second main body portion 124B, and the raised portion 124C protrudes upward compared to the first main body portion 124A and the second main body portion 124B, wherein the raised portion 124C is fit and fixed to the lower side surface 1220 of the middle channel 122, and the first main body portion 124A and the second main body portion 124B are both fit and fixed to the floor body 121.

[0189] The first body portion 124A and the second body portion 124B are spaced apart in the left-right direction Y. The first body portion 124A and the second body portion 124B are connected by a raised portion 124C. The raised portion 124C protrudes upward compared to the first body portion 124A and the second body portion 124B. The raised portion 124C is fit and fixed to the lower side surface 1220 of the middle channel 122, that is, the raised portion 124C can support the lower side surface 1220 of the middle channel 122. The first body portion 124A and the second body portion 124B can fit with the floor body 121. The first body portion 124A and the second body portion 124B can support the floor body 121. The first body portion 124A and the second body portion 124B can be connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126, respectively.

[0190] Specifically, the raised portion 124C is fitted and fixed to the lower side surface 1220 of the middle channel 122, and the first main body portion 124A and the second main body portion 124B are both fitted and fixed to the floor body 121, which can reduce the single-point force situation of the floor body 121, reduce the risk of stress concentration in the floor body 121, and increase the service life of the floor body 121, thereby increasing the service life of the entire vehicle.

[0191] Figure 18 A partial structural diagram of the first floor beam 124 in a specific embodiment is shown, wherein the third suspension mounting bracket 127 is disposed on the raised portion 124C, so that the third suspension 123 is disposed on the raised portion 124C through the third suspension mounting bracket 127 .

[0192] Figure 19 A schematic diagram of a partial structure of a range-extended vehicle body in a specific embodiment is shown; Figure 20 FIG. 1 is an exploded schematic diagram of a partial structure of the first floor cross member 124 in a specific embodiment.

[0193] like Figure 19 and Figure 20As shown, in one specific embodiment, the first body part 124A and the second body part 124B each include a first connecting part 1241 and a second connecting part 1242, and the first connecting part 1241 is connected between the protruding part 124C and the second connecting part 1242.

[0194] The first connecting part 1241 can be connected to the protruding part 124C and the second connecting part 1242 by means of screws or welding, so as to improve the connection strength and the structural stability of the first floor cross beam 124.

[0195] In the present embodiment, the first body part 124A and the second body part 124B each include the first connecting part 1241 and the second connecting part 1242, so that the first connecting part 1241, the second connecting part 1242 and the protruding part 124C can be manufactured separately, facilitating the replacement of the first connecting part 1241, the second connecting part 1242 or the protruding part 124C, improving the design freedom of the first floor cross beam 124, and making the first floor cross beam 124 applicable to different vehicle models and improving the use range of the first floor cross beam 124.

[0196] Specifically, when manufacturing the protruding part 124C, an insert block can be arranged on the mold base of the preparation tool, and the insert block is a replaceable structure, so that the insert block can be added, reduced or replaced according to actual needs, so as to adjust the structural size of the protruding part 123C to adapt to different vehicle models. In this way, the mold cost can be reduced, thereby reducing the development cost. The first connecting part 1241 and the second connecting part 1242 of the first body part 124A and the second body part 124B can also be manufactured by arranging an insert block on the mold base of the preparation tool or by using different specifications and sizes of molds, so as to adjust the first connecting part 1241 and the second connecting part 1242 to adapt to different vehicle models and improve the design freedom.

[0197] In addition, the structural strength of the first connecting part 1241, the second connecting part 1242 and the protruding part 124C can also be set to be different, so that the first floor cross beam 124 assembled therefrom has a variable strength structure, so that the first floor cross beam 124 can adjust the structural strength according to the stress condition thereof at different positions, so as to reduce the overall weight of the first floor cross beam 124 and save costs.

[0198] In some embodiments, the first connecting part 1241, the second connecting part 1242 and the protruding part 124C can be formed by using different materials, different thicknesses or different manufacturing processes, so that the structural strength of the first connecting part 1241, the second connecting part 1242 and the protruding part 124C is different.

[0199] In one specific embodiment, as Figure 19As shown, the strength of the material of the protrusion 124C is higher than the strength of the material of the first connection part 1241 and the second connection part 1242 , or the thickness of the protrusion 124C is greater than the thickness of the first connection part 1241 and the second connection part 1242 .

[0200] In this embodiment, the structural strength of protrusion 124C is greater than that of first connection portion 1241 and second connection portion 1242, thereby enhancing the support provided by protrusion 124C to central channel 122 and ensuring the structural stability of floor assembly 120. Specifically, when the material strength of protrusion 124C is greater than that of first connection portion 1241 and second connection portion 1242, the structural strength of protrusion 124C is greater than that of first connection portion 1241 and second connection portion 1242, thereby enhancing the support provided by protrusion 124C to central channel 122. Furthermore, protrusion 124C can be made thinner, thereby reducing the space occupied by protrusion 124C and improving the space utilization of central channel 122. When the thickness of the protrusion 124C is greater than the thickness of the first connection part 1241 and the second connection part 1242, the structural strength of the protrusion 124C made of the same material and the first connection part 1241 and the second connection part 1242 can be made higher to ensure the supporting effect of the protrusion 124C on the central channel 122.

[0201] One end of the second connecting portion 1242 of the first body portion 124A, remote from the first connecting portion 1241, is connected to the first floor longitudinal beam 125, and one end of the second connecting portion 1242 of the second body portion 124B, remote from the first connecting portion 1241, is connected to the second floor longitudinal beam 126. This improves the connection strength between the first floor cross member 124 and the first and second floor longitudinal beams 125 and 126, and also improves the connection stability of the first floor cross member 124 to the floor body 121, thereby ensuring the supporting effect of the first floor cross member 124 on the floor body 1.

[0202] In a specific embodiment, Figure 19 and Figure 20 As shown, the first connecting portion 1241 includes a first bending segment 1241A and a second bending segment 1241B that are bent relative to each other. The first bending segment 1241A is connected to the protruding portion 124C, and the second bending segment 1241B is connected to the second connecting portion 1242 .

[0203] In this embodiment, the first connection portion 1241 includes a first bent section 1241A and a second bent section 1241B that are relatively bent, which can increase the connection area between the first connection portion 1241 and the protrusion 124C and the second connection portion 1242, thereby improving the connection strength at the connection between the two components and improving the structural stability of the first floor beam 124.

[0204] Among them, the manufacturing materials and manufacturing processes of the first connecting part 1241, the second connecting part 1242 or the raised part 124C can be different. Specifically, tubular materials can be used to form them separately through an expansion process, or they can be formed separately through die-casting. Of course, they can also be prepared and formed by other methods, so that different components of the first floor beam 124 can achieve different coordination with the floor body 121 or the third suspension mounting bracket 127, further improving the design freedom of the extended-range vehicle body. The specific settings can be made according to actual needs and are not limited here.

[0205] Figure 21 FIG. 1 is a partial structural diagram of a floor assembly 120 in a specific embodiment.

[0206] In a specific embodiment, Figure 19 and Figure 20 As shown, the first floor cross members 124 are symmetrically arranged in the left-right direction Y.

[0207] In this embodiment, Figures 19 to 21 As shown, the first floor cross member 124 is symmetrically arranged in the left-right direction Y, which can realize the modularization of the first floor cross member 124. The first floor cross member 124 can be moved in the central channel 122 on the floor body 121 along the front-back direction X. Therefore, the first floor cross member 124 can adapt to different vehicle models, expand the applicability of the first floor cross member 124, and reduce development costs.

[0208] Among them, the first connection part 1241 of the first main body part 124A and the second main body part 124B can be set to be the same, so as to achieve the commonality of the first connection part 1241 in the first main body part 124A and the second main body part 124B. In this way, the first connection part 1241 can be manufactured in a unified manner, reducing manufacturing molds and further reducing manufacturing costs.

[0209] In some other embodiments, the first connecting portion 1241, the second connecting portion 1242, and the raised portion 124C of the first floor cross member 124 may also be integrally formed to facilitate mass production of the first floor cross member 124 and reduce manufacturing costs. Specifically, they may be integrally formed using a tubular material through an expansion process, or through die-casting. Of course, other methods are also possible, and the specific configuration can be tailored to actual needs and is not limited here.

[0210] In the related art, since the range extender assembly in an extended-range vehicle integrates a generator, an electric motor, and a generator controller, the range extender assembly is large in size and requires a large amount of front cabin space, resulting in the space defined by the front cabin assembly having to be large enough to meet the installation requirements of the range extender.

[0211] In this embodiment, please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17 As shown, the extended-range vehicle body 100 includes a front cabin assembly 110, a floor assembly 120 and a range extender assembly 130. The front cabin assembly 110 defines a first accommodating space 110A. The floor assembly 120 is located behind the front cabin assembly 110. The floor assembly 120 includes a floor body 121 and a middle channel 122 arranged on the floor body 121. The middle channel 122 defines a second accommodating space 122A. The second accommodating space 122A is connected to the first accommodating space 110A. A portion of the range extender assembly 130 is arranged in the first accommodating space 110A, and another portion of the range extender assembly 130 is arranged in the second accommodating space 122A. Since a portion of the range extender assembly 130 is disposed in the first accommodating space 110A and another portion of the range extender assembly 130 is disposed in the second accommodating space 122A, the space below the front cabin assembly 110 and the floor assembly 120 of the range-extended vehicle body 100 can be fully utilized. Even a vehicle with a smaller front cabin can be designed as a range-extended vehicle.

[0212] Among them, the front cabin assembly 110 defines a first accommodating space 110A, and the floor assembly 120 is located behind the front cabin assembly 110. That is, the floor assembly 120 is arranged behind the first accommodating space 110A. The floor assembly 120 includes a floor body 121 and a central channel 122 arranged in the floor body 121. Due to the complex structural limitations of the extended-range vehicle body 100 itself, the cross-sectional shape of the floor body 121 along the front-to-rear direction X of the floor body 121 can be roughly a "J" shape, so that a central channel 122 will be formed under the floor body 121. The central channel 122 defines a second accommodating space 122A. The first accommodating space 110A and the second accommodating space 122A are connected. The second accommodating space 122A is behind the first accommodating space 110A, and the first accommodating space 110A is in front of the second accommodating space 122A. A portion of the range extender assembly 130 is disposed in the first accommodation space 110A, and another portion of the range extender assembly 130 is disposed in the second accommodation space 122A. That is, the range extender assembly 130 spans the first accommodation space 110A and the second accommodation space 122A.

[0213] For vehicles with a smaller front engine compartment assembly 110, the smaller front engine compartment assembly 110 design means less resistance when air flows through this area, helping to improve the vehicle's aerodynamic performance. This design can reduce wind resistance during vehicle operation, thereby improving fuel economy and reducing energy loss during driving. The smaller front engine compartment assembly 110 can also reduce air turbulence, making the vehicle more stable at high speeds, helping to improve top speed and acceleration performance. Furthermore, the smaller front engine compartment assembly 110 means that fewer materials and components are required to construct it, which helps reduce the vehicle's curb weight and effectively lowers the vehicle's overall manufacturing cost.

[0214] The front engine compartment assembly 110 is relatively small, and generally, the first storage space 110A is also relatively small, while the range extender assembly 130 is relatively large. Placing a portion of the range extender assembly 130 in the first storage space 110A and the remaining portion in the second storage space 122A significantly reduces the volume occupied by the range extender assembly 130 in the first storage space 110A. This allows vehicles with smaller front engine compartment assemblies 110 (and smaller first storage space 110A) to accommodate the larger range extender assembly 130, expanding the range of vehicles for which the range extender assembly 130 is applicable. For example, for a vehicle with a larger front cabin assembly 110 and a larger first storage space 110A, placing a portion of the range extender assembly 130 in the first storage space 110A and extending the remaining portion of the range extender assembly 130 into the second storage space 122A can effectively reduce the space occupancy of the front cabin assembly 110. The remaining space within the front cabin assembly 110 can then be used to accommodate storage space or other components, significantly improving the space utilization within the vehicle. Furthermore, it can also expand the space available to passengers and enhance passenger comfort. Furthermore, placing the range extender assembly 130 within the first storage space 110A and the second storage space 122A provides a larger storage space for the range extender assembly than placing the range extender separately in the first storage space 110A or the second storage space 122A. This facilitates the dissipation of heat generated by the range extender assembly 130 during operation, thereby increasing the service life and operating efficiency of the range extender assembly 130.

[0215] For example, this structure can shorten the front overhang length of the range extender assembly 130 in the front cabin assembly 110 by more than 170 mm, that is, the passenger compartment space can be increased by more than 170 mm, thereby improving the internal space utilization of the range-extended vehicle body.

[0216] In some embodiments, the extended-range vehicle body further includes a fuel tank 190 , which is disposed between the battery 170 and the electric motor 180 .

[0217] Specifically, part of the range extender assembly 130 is arranged in the first accommodating space 110A defined by the front cabin assembly 110, and the other part of the range extender assembly 130 is arranged in the second accommodating space 122A defined by the middle channel 122, so that the front cabin assembly 110 can be used in a vehicle model with a smaller front end, and the range extender assembly 130 can be used in a plurality of vehicle models, thereby expanding the application range of the range extender assembly 130 and improving the utilization rate of the vehicle interior space.

[0218] Please refer to Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 15 、 Figure 16 and Figure 17 In the embodiment, the range extender assembly 130 includes an engine 131 and a generator 132, the engine 131 is power-connected with the generator 132, the engine 131 is located at the front side of the generator 132, part of the engine 131 is arranged in the first accommodating space 110A, and the other part of the engine 131 and the generator 132 are arranged in the second accommodating space 122A.

[0219] The engine 131 of the range extended vehicle is mainly used for power generation, rather than directly driving the vehicle, the range extender assembly 130 can include an engine 131 and a generator 132, the engine 131 and the generator 132 are power-connected, the mechanical energy of the engine 131 crankshaft rotation is converted into electric energy by the generator 132, the generator 132 is internally provided with a magnetic field and a conductor coil, when the conductor coil rotates in the magnetic field, an electromotive force will be generated at both ends of the conductor coil, thereby generating an electric current to power the battery 170, generally, when the battery 170 has sufficient power, the electric motor 180 directly uses the power of the battery 170 to drive the vehicle, when the battery 170 has insufficient power, the engine 131 and the generator 132 operate cooperatively, the engine 131 starts and drives the generator 132 to generate power, and the generator 132 charges the battery 170 or directly powers the electric motor 180.

[0220] The battery 170 is arranged in the middle of the vehicle, the engine 131 is located in front of the generator 132, that is, along the front-rear direction X of the vehicle, the engine 131 is farther away from the battery 170, the generator 132 is closer to the battery 170, the motor 180 is arranged behind the battery 170, and the generator 132 is also closer to the battery 170 relative to the engine 131. In this way, on the one hand, the circuit layout inside the vehicle can be simplified, and the probability of vehicle failure can be reduced. On the other hand, the positions of the generator 132, the battery 170 and the motor 180 are closer to each other, which can also reduce the transmission loss of electric energy, improve the power generation efficiency, and further improve the cruising range of the range-extender vehicle.

[0221] Specifically, part of the engine 131 is arranged in the first accommodating space 110A, and the other part of the engine 131 and the generator 132 are arranged in the second accommodating space 122A. Since the front engine assembly 110 defines the first accommodating space 110A, the second accommodating space 122A is arranged below the floor assembly 120. When the engine 131 is in operation, it will generate a large amount of noise and vibration. Compared with arranging the engine 131 entirely in the second accommodating space 122A, arranging part of the engine 131 in the first accommodating space 110A can obviously greatly reduce the influence of the vibration and noise generated by the engine 131 on passengers, and greatly improve the use comfort of the vehicle.

[0222] Please refer to Figures 22 to 25 , Figure 22 a structural schematic view of the range-extender assembly 130 provided in an embodiment of the present application; Figure 23 a partial enlarged view of the range-extender assembly 130 provided in an embodiment of the present application; Figure 24 a partial enlarged view of the range-extender assembly 130 provided in an embodiment of the present application; Figure 25 The third suspension 123 is shown.

[0223] In the embodiment, the range-extender assembly 130 further includes a generator controller 133, the generator 132 includes a first housing 140, the motor controller includes a second housing 141, the range-extender assembly 130 further includes a third housing 142, and the third housing 142 and the first housing 140 jointly define a first space accommodating the stator and the rotor, and the third housing 142 and the second housing 141 jointly define a second space accommodating electrical components.

[0224] The engine 131 is connected to the generator 132 and is positioned in front of the generator 132. The generator 132 is connected to the generator controller 133 and is positioned in front of the generator controller 133. The first housing 140, the second housing 141, and the third housing 142 are all mounted on the range extender assembly 130. The first housing 140 and the third housing 142 define a first space for accommodating the stator and rotor (generator 132). The second housing 141 and the third housing 142 together define a second space for accommodating electrical components.

[0225] Specifically, the first shell 140, the second shell 141 and the third shell 142 jointly define an accommodating space for the generator 132 and the generator controller 133. The generator 132 and the generator controller 133 share the third shell 142, which can greatly reduce the manufacturing cost of the generator 132 and the generator controller 133 and improve the assembly efficiency of the generator 132 and the generator controller 133.

[0226] Please refer to Figures 22 to 25 In this embodiment, a recessed portion 140A recessed upward is provided on the upper side surface of the first shell 140, and the first shell 140 is also provided with a plurality of reinforcing ribs 160, each of which is connected to the inner wall surface of the recessed portion 140A and extends along the front-to-back direction X.

[0227] The upper side of the first housing 140 is provided with an upwardly recessed portion 140A. Multiple reinforcing ribs 160 are also provided on the recessed portion 140A to improve the vehicle's system modal response and enhance the support strength of the range extender assembly 130. For example, the vehicle's system modal response can be increased to 316 Hz, and the support strength of the range extender assembly 130 can be increased by 30%, thereby enhancing the vehicle's overall performance.

[0228] In some embodiments, four mounting holes 200 may be further provided on the third housing 142 , and the third suspension 123 is fixedly connected to the four mounting holes 200 , so that the range extender assembly 130 can be suspended on the third suspension 123 .

[0229] Please refer to Figures 22 to 25 In this embodiment, the range extender assembly includes an engine 131 and a generator 132. The engine 131 is power-connected to the generator 132. The engine 131 is located in front of the generator 132. The engine 131 has a first power output shaft 131A, and the generator 132 has a first power input shaft 132A. The first power output shaft 131A is parallel to the second power input shaft and both extend in the front-to-back direction X.

[0230] The engine 131 and the generator 132 are power-connected. The engine 131 is located in front of the generator 132. The first power output shaft 131A of the engine 131 is connected to the first power input shaft 132A of the motor 180. The first power output shaft 131A of the engine 131 rotates, driving the first power input shaft 132A of the generator 132 to rotate.

[0231] That is, the engine 131 and the generator 132 are both installed in the front-to-back direction X, thereby reducing the space occupied in the left-to-right direction Y of the front nacelle assembly 110 .

[0232] The first power output shaft 131A can be arranged above the first power input shaft 132A. The first power output shaft 131A and the first power input shaft 132A are parallel and extend in the front-to-back direction X, which can enable the power of the engine 131 to be transmitted to the generator 132 more smoothly, improve the overall mode of the vehicle system, and reduce the vibration of the range extender assembly 130.

[0233] Please refer to Figures 22 to 25 In this embodiment, the extended-range vehicle body further includes a speed increaser 150, which includes a first driving gear 151 and a first driven gear 152 that are meshed with each other. The first driving gear 151 is power-connected to the engine 131, and the first driven gear 152 is power-connected to the generator 132. The rotation axis of the first driving gear 151 is spaced apart from the rotation axis of the second driving gear in the up-down direction Z.

[0234] The first driving gear 151 of the speed increaser 150 is connected to the engine 131, and the first driven gear 152 of the speed increaser 150 is connected to the generator 132. In other words, the power output by the engine 131 is transmitted to the first driving gear 151 of the speed increaser 150, and the first driving gear 151 transmits the power to the first driven gear 152, and then the first driven gear 152 transmits the power to the generator 132. For example, the number of teeth of the first driving gear 151 is usually less than that of the driven gear.

[0235] The rotation axis of the first driving gear 151 and the rotation axis of the first driven gear 152 are spaced apart in the up-down direction Z, which can make full use of the space of the front cabin assembly 110 in the up-down direction Z, reduce the space occupied by the speed increaser 150 in the left-right direction Y of the front cabin assembly 110, and of course make the range extender assembly 130 more compact in the front-to-back direction X, and significantly reduce the length of the range extender assembly 130 in the front-to-back direction X, thereby expanding the scope of application of the range extender assembly 130, so that models with smaller front cabin assemblies 110 can also be installed with the range extender assembly 130.

[0236] like Figure 26As shown, the present application also provides a method for manufacturing a range-extended vehicle body, which is used to manufacture the range-extended vehicle body 100 in any of the above embodiments. The method for manufacturing the range-extended vehicle body 100 includes:

[0237] Step S1 : manufacturing the front cabin assembly 110 .

[0238] In this step, the front cabin assembly 110 disclosed in the embodiment of the present application may include a first accommodating space, a first suspension, a second suspension, a subframe, a first front cabin longitudinal beam, and a second front cabin longitudinal beam.

[0239] Step S2, manufacturing the floor assembly 120, such as Figure 21 As shown, the floor assembly 120 is provided with a central channel 122 .

[0240] In this step, the floor assembly 120 disclosed in the embodiment of the present application may further include a floor body, a second accommodating space, a third suspension, a first floor crossbeam, a first floor longitudinal beam, and a second floor longitudinal beam.

[0241] Step S3, such as Figures 2 to 5 As shown, the floor assembly 120 is connected to the front cabin assembly 110 .

[0242] In this step, the floor assembly 120 and the front cabin assembly 110 are connected to form a whole, so that the range extender assembly 130 can be subsequently connected to the floor assembly 120 and the front cabin assembly 110 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0243] Step S4, as Figure 2 、 Figure 7 and Figure 8 As shown, the first suspension 111, the second suspension 112 and the third suspension 123 are connected to the range extender assembly 130; wherein the first suspension 111 and the second suspension 112 are spaced apart in the left-right direction Y, and the third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z.

[0244] In this step, the first suspension 111, the second suspension 112 and the third suspension 123 are connected to the range extender assembly 130 to form a whole, so that the range extender assembly 130 can be subsequently connected to the overall structure formed by the floor assembly 120 and the front cabin assembly 110 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0245] Step S5, as Figure 2 、 Figure 3 、 Figure 5 、 Figure 6 、 Figure 16 and Figure 17As shown, the first suspension 111 and the second suspension 112 are connected to the front cabin assembly 110 , and the third suspension 123 is connected to the middle channel 122 .

[0246] In this step, the range extender assembly 130 is connected to the integral structure formed by the floor assembly 120 and the front cabin assembly 110 through the first suspension 111 , the second suspension 112 , and the third suspension 123 , so that the range extender assembly 130 is installed on the floor assembly 120 and the front cabin assembly 110 .

[0247] In this embodiment, a first suspension 111 and a second suspension 112 are provided on the front cabin assembly 110, and a third suspension 123 is provided on the middle channel 122. The first suspension 111 and the second suspension 112 are arranged in the first accommodating space 110A, and the third suspension 123 is arranged in the second accommodating space 122A. The first suspension 111 and the second suspension 112 are arranged in front of the third suspension 123, and the third suspension 123 is arranged behind the first suspension 111 and the second suspension 112. The first suspension 111 and the second suspension 112 are spaced apart in the front-to-back direction X. The first suspension 111, the second suspension 112 and the third suspension 123 together form a triangular structure. The range extender assembly 130 is fixed to the front cabin assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0248] Because the first, second, and third mounts 111, 112, and 123 together form a triangular structure to secure the range extender assembly 130, the triangular mount design allows the three mounting points to be evenly distributed around the range extender assembly 130, forming a stable triangular support structure. This effectively resists various torsional and vibrational forces exerted on the range extender assembly 130 during vehicle operation, thereby maintaining the operational stability and reliability of the range extender assembly 130 and improving the safety and reliability of the vehicle. Furthermore, the triangular mount attenuates vibrations generated by the range extender assembly 130 during operation, reducing their impact on other components of the range extender vehicle body 100, thereby improving vehicle noise and enhancing vehicle comfort. For example, this can reduce vehicle noise by 3 decibels, enhancing vehicle comfort.

[0249] The range extender assembly 130 is secured to the front cabin assembly 110 and the floor assembly 120 via a triangular mount, allowing for independent installation and removal of the range extender assembly 130. This facilitates repair and replacement of the range extender assembly 130 in the event of a malfunction, thereby improving vehicle manufacturing and assembly efficiency. Furthermore, the triangular mount layout is compact, maximizing space within the range-extended vehicle body 100, minimizing interference with other components, and improving overall vehicle space utilization.

[0250] The range extender assembly 130 is fixed to the front cabin assembly 110 and the floor assembly 120 through a triangular suspension, which is also beneficial to reduce power loss during transmission, improve the power output efficiency of the range extender assembly 130, and further enhance the overall performance of the vehicle.

[0251] The third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z, respectively. That is, the first suspension 111 and the second suspension 112 may be below the third suspension 123, and the third suspension 123 is above the first suspension 111 and the second suspension 112. That is, the first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, thereby improving the stability and controllability of the vehicle and making the center of mass distribution of the range extender assembly 130 more reasonable. Furthermore, different mount positions can optimize vibration isolation in different directions. The first and second mounts 111, 112 are positioned below the range extender assembly 130, facilitating horizontal and vertical vibration suppression. The third mount 123 is positioned above the range extender assembly 130, suppressing longitudinal vibration. This layout improves vibration isolation, reduces the impact of vibration on the range-extended vehicle body and cab, lowers the probability of vehicle failure, and improves operational stability. For example, it can reduce the probability of vehicle failure by 20%, improve operational stability, and lower user costs.

[0252] Furthermore, the range extender assembly 130 in the embodiment of the present application can be assembled with the first mount 111, the second mount 112, and the third mount 123, and then integrated with the front cabin assembly 110 and the floor assembly 120. This ensures that the relative positions of the three mounting points in the free state meet the positional accuracy requirements, reduces the positional tolerance during the assembly process, and ensures the positional accuracy of the range extender assembly 130. For example, the positional tolerance can be reduced to within 2 mm to ensure the positional accuracy of the range extender assembly.

[0253] In a specific embodiment, Figure 27 As shown, step S2, manufacturing the floor assembly 120, specifically includes:

[0254] Step S21 : manufacturing the floor slab 500 .

[0255] In this step, the floor material 500 may be a flat plate structure or a nearly flat plate structure with a certain thickness.

[0256] Step S22, as Figure 28 As shown, the floorboard blank 500 is subjected to a drawing process to form the floorboard body 121 and the middle channel 122 , and a material storage convex hump 501 is formed on the middle channel 122 .

[0257] In this step, the floor blank 500 can be placed between the drawing die 301 and the drawing punch 302, and the floor blank 500 is pressurized by the drawing die 301 and the drawing punch 302, so that the floor blank 500 is drawn to form the floor body 121 and the middle channel 122, and a material storage bulge 501 is formed on the middle channel 122.

[0258] In step S23 , the floorboard blank 500 is shaped, and the material storage convex bump 501 is pressed downward to form an arc-shaped corner 129 at the connection between the middle channel 122 and the floorboard body 121 .

[0259] In this step, the floor blank 500 after drawing forming is placed between the shaping die 401 and the shaping punch 402, and the floor blank 500 is pressurized by the shaping die 401 and the shaping punch 402, and the material storage convex 501 is pressed down to form the arc corner 129 at the connection between the middle channel 122 and the floor body 121, thereby forming the floor assembly 120.

[0260] In order to accommodate part of the range extender assembly 130, the middle channel 122 of the floor assembly 120 is relatively deep. Therefore, during the manufacturing process of the floor assembly 120, cracks may easily appear on the middle channel 122 due to the excessive drawing depth and excessive draft angle when drawing the floor blank, resulting in a low production yield.

[0261] In this embodiment, Figure 28 and Figure 29 As shown, a floorboard blank 500 is drawn to form a floorboard body 121 and a central channel 122, and a material storage bump 501 is formed on the central channel 122. When the drawn floorboard blank 500 is shaped, the material storage bump 501 is pressed downward to form a curved corner 129 at the junction of the central channel 122 and the floorboard body 121, thereby forming the floor assembly 120 to meet the requirements of the extended-range vehicle body 100.

[0262] This manufacturing process is simple and facilitates mass production of the floor assembly 120. Specifically, by forming a material storage bump 501 on the central channel 122 during the draw-forming process of the floor blank 500, a step-like structure can be created on the sidewalls of the central channel 122. This ensures the overall depth of the central channel 122 while preventing an excessively sharp draft angle. This improves forming conditions, reduces the risk of cracking in the central channel 122 during the draw-forming process, increases the manufacturing yield, and saves manufacturing costs. For example, the manufacturing yield of the central channel 122 can be increased to 100%, preventing cracking in the central channel 122 during the draw-forming process.

[0263] Among them, such as Figure 28As shown, corresponding protrusions and depressions can be provided on the drawing punch 302 and the drawing die 301 at positions corresponding to the material storage bumps 501 so that the floor blank 500 can form material storage bumps 501 on the middle channel 122 during the drawing process.

[0264] In addition, if Figure 29 As shown, by providing a shaping die 401 and a shaping punch 402 that meet the use requirements of the extended-range vehicle body 100, the material storage convex 501 can be pressed downward under the action of the shaping die 401 and the shaping punch 402, thereby shaping the curved corner 129 at the connection between the central channel 122 and the floor body 121. The convex structure in the shaping die 401 and the shaping punch 402 that shapes the material storage convex 501 can be a detachable insert structure mounted on the shaping die 401 and the shaping punch 402, so as to facilitate shaping of material storage convex 501 of different sizes, further saving manufacturing costs. In addition, a guide plate can be provided on the shaping insert structure to ensure that the movement trajectory of the shaping insert does not deviate, thereby ensuring the shaping effect.

[0265] Among them, between step S22 and step S23, the manufacturing of the floor assembly 120 may also include steps such as trimming, punching, fine trimming, and flanging, which can be specifically set according to actual needs and are not limited here.

[0266] In a specific embodiment, Figure 28 and Figure 29 As shown, the arc length of the material storage bump 501 is equal to or approximately equal to the arc length of the corresponding curved corner 129. If the arc length of the material storage bump 501 is too long, when the material storage bump 501 is pressed down to form the curved corner 129 at the connection between the central channel 122 and the floor body 121, there is a risk of wrinkling and stacking of the material at the curved corner 129. If the arc length of the material storage bump 501 is too short, when the material storage bump 501 is pressed down to form the curved corner 129 at the connection between the central channel 122 and the floor body 121, the formed curved corner 129 is likely to be too thin, reducing the structural strength or causing the risk of cracking at the curved corner 129.

[0267] Therefore, when the arc length of the material storage bulge 501 is equal to or approximately equal to the arc length of the corresponding arc corner 129, when the material storage bulge 501 is pressed down to form the arc corner 129 at the connection between the middle channel 122 and the floor body 121, the overall thickness of the floor assembly 120 can be made uniform, avoiding the risk of wrinkling, stacking or cracking at the arc corner 129, further improving the production yield and saving production costs.

[0268] Preferably, the arc length of the material storage convex hump 501 is equal to the arc length of the corresponding arc corner 129 to ensure that the overall thickness of the formed floor assembly is uniform and to avoid wrinkling, stacking or cracking at the arc corner 129.

[0269] It should also be noted that the terms "comprises," "includes," or any other variations thereof are intended to encompass non-exclusive inclusion, such that a process, method, commodity, or apparatus that includes a series of elements includes not only those elements but also other elements not explicitly listed, or includes elements inherent to such process, method, commodity, or apparatus. In the absence of further limitations, an element defined by the phrase "comprises a ..." does not exclude the presence of other identical elements in the process, method, commodity, or apparatus that includes the element.

[0270] The various embodiments in this specification are described in a progressive manner. Similar parts between the various embodiments can be referred to in conjunction with each other. Each embodiment focuses on the differences between the other embodiments. In particular, the system embodiments are generally similar to the method embodiments, so the description is relatively simple. For relevant parts, refer to the description of the method embodiments.

[0271] The foregoing is merely an embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should all be included within the scope of the claims of the present application.

[0272] Although the embodiments of the present application have been described with reference to the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present application, and such modifications and variations shall fall within the scope defined by the appended claims.

Claims

1. A range-extended vehicle body, characterized in that: include: a front nacelle assembly, wherein the front nacelle assembly is provided with a first suspension and a second suspension, wherein the first suspension and the second suspension are spaced apart in a left-right direction; a floor assembly located behind the front cabin assembly, the floor assembly comprising a floor body and a central channel disposed in the floor body; a third suspension disposed on the central channel, the third suspension being spaced apart from the first suspension and the second suspension in a front-to-rear direction, and the third suspension being spaced apart from the first suspension and the second suspension in a top-to-bottom direction; A range extender assembly is fixed to the front cabin assembly and the floor assembly through the first suspension, the second suspension, and the third suspension.

2. The extended-range vehicle body according to claim 1, characterized in that: The third suspension includes a bushing seat, an elastic member and an inner core, the elastic member is installed in the bushing seat, and the inner core is installed in the elastic member; the inner core is provided with a first mounting hole; A third suspension mounting bracket is provided on the middle channel, and the third suspension mounting bracket is provided with a second mounting hole; the second mounting hole is connected to the first mounting hole by a mounting bolt.

3. The extended-range vehicle body according to claim 2, characterized in that: The diameter of the first mounting hole is larger than the diameter of the mounting bolt; and / or, A center position of the first mounting hole is lower than a center position of the second mounting hole in a vertical direction.

4. The extended-range vehicle body according to claim 2, characterized in that: The elastic member includes a mounting portion and a connecting arm, one end of the connecting arm is connected to the inner wall of the bushing seat, and the other end of the connecting arm is connected to the mounting portion; the mounting portion includes a mounting cavity, and the inner core is installed in the mounting cavity.

5. The extended-range vehicle body according to claim 4, characterized in that: The inner core includes a first arcuate surface, a second arcuate surface, and a connecting surface connecting the first arcuate surface and the second arcuate surface; the diameter of the first arcuate surface is greater than the diameter of the second arcuate surface; The connecting arm is connected to corresponding positions of the second arc-shaped surface and the connecting surface on the mounting portion.

6. The extended-range vehicle body according to claim 4, characterized in that: The elastic member further includes a first buffer portion and a second buffer portion; A first gap is formed between the first buffer portion, the connecting arm, and the mounting portion; a second gap is formed between the second buffer portion, the connecting arm, and the mounting portion; The first gap and the second gap are spaced apart in the up-down direction.

7. The extended-range vehicle body according to claim 2, characterized in that: The third suspension also includes a second main board, one end of which is connected to the bushing seat, and the other end of the second main board is provided with a mounting surface, which is connected to the range extender assembly.

8. The extended-range vehicle body according to claim 7, characterized in that: The thickness of the second main board is 4 mm to 5 mm.

9. The extended-range vehicle body according to any one of claims 1 to 8, characterized in that: The first suspension and the second suspension each include a suspension body, a connecting plate, a first main plate and a nut plate; One end of the suspension body is connected to the front nacelle assembly, and the other end is connected to the first main board via a connecting plate; The nut plate is arranged on the first main board and is connected to the range extender assembly by bolts.

10. The extended-range vehicle body according to claim 9, characterized in that: The thickness of the first main board is 4 mm to 5 mm; and / or, The thickness of the nut plate is 3.5 mm to 4.5 mm; and / or, The thickness of the connecting plate is 4 mm to 5 mm.

11. The extended-range vehicle body according to any one of claims 1 to 8, characterized in that: The floor assembly further includes a first floor cross member extending in the left-right direction, and at least a portion of the first floor cross member is fixed to the lower side of the central channel, and the third suspension is arranged on the first floor cross member.

12. The extended-range vehicle body according to claim 11, characterized in that: The first floor cross member includes a first body portion, a second body portion, and a raised portion connected between the first body portion and the second body portion, wherein the raised portion protrudes upward relative to the first body portion and the second body portion; The raised portion is fixedly attached to the lower side of the middle channel, and the first main body portion and the second main body portion are both fixedly attached to the floor body; and the third suspension is arranged on the raised portion.

13. The extended-range vehicle body according to claim 12, characterized in that: The first body portion and the second body portion each include a first connecting portion and a second connecting portion, wherein the first connecting portion is connected between the protruding portion and the second connecting portion.

14. The extended-range vehicle body according to claim 13, characterized in that: The strength of the material of the protruding portion is higher than the strength of the material of the first connecting portion and the second connecting portion; Alternatively, the thickness of the protruding portion is greater than the thickness of the first connecting portion and the second connecting portion.

15. The extended-range vehicle body according to claim 11, characterized in that: The first floor crossbeams are symmetrically arranged in the left-right direction.

16. The vehicle body according to any one of claims 1 to 8, characterized in that: The front cabin assembly defines a first accommodating space, the central passage defines a second accommodating space, and the second accommodating space is communicated with the first accommodating space; The range extender assembly includes an engine and a generator, the engine is connected to the generator in a power-connected manner, and the engine is located in front of the generator; A portion of the engine is disposed in the first accommodation space, and another portion of the engine and the generator are disposed in the second accommodation space.

17. The extended-range vehicle body according to claim 16, characterized in that: The range extender assembly further includes a generator controller, the generator includes a first housing, and the motor controller includes a second housing; The range extender assembly further includes a third housing, wherein the third housing and the first housing together define a first space for accommodating the stator and rotor, and the third housing and the second housing together define a second space for accommodating electrical components; The upper side surface of the first shell is provided with a recessed portion recessed upward; The first shell is further provided with a plurality of reinforcing ribs, each of which is connected to the inner wall surface of the recessed portion and extends along the front-to-back direction.

18. A method for manufacturing a range-extended vehicle body, characterized in that: For manufacturing a vehicle body according to any one of claims 1 to 17, the manufacturing method of the vehicle body comprises: Manufacturing of the front nacelle assembly; manufacturing a floor assembly, wherein the floor assembly is provided with a central channel; connecting the floor assembly to the front cabin assembly; Connecting a first suspension, a second suspension, and a third suspension to the range extender assembly; wherein the first suspension and the second suspension are spaced apart in the left-right direction, and the third suspension is spaced apart from the first suspension and the second suspension in the up-down direction; The first suspension and the second suspension are connected to the front cabin assembly, and the third suspension is connected to the central channel.

19. The method for manufacturing a range-extended vehicle body according to claim 18, wherein: The manufacturing of the floor assembly specifically includes: manufacturing floor slabs; Performing a drawing process on the floor blank to form the floor body and the central channel, and forming a material storage convex hump on the central channel; The floor blank is shaped and the material storage convex bump is pressed downward to form an arc-shaped corner at the connection between the middle channel and the floor body.

20. The method for manufacturing a range-extended vehicle body according to claim 19, wherein: The arc length of the material storage convex hull is equal to the arc length of the corresponding arc corner.

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