Extended-range automobile body and method of manufacturing the same

Abstract

The application relates to a range-extender automobile body and a manufacturing method thereof. The automobile body comprises a front engine compartment assembly, a floor assembly and a range-extender assembly. The first suspension and the second suspension are arranged on the front engine compartment assembly. The floor assembly comprises a middle channel. The third suspension is arranged on the middle channel. The third suspension is spaced apart from the first suspension and the second suspension in the front-rear direction and the up-down direction. The floor assembly blank is subjected to drawing forming processing to form a floor body and a middle channel. A storage convex is formed on the middle channel. The floor blank is subjected to shaping processing. The arc length of the storage convex is equal to the arc length of the corresponding arc-shaped corner. The structure and the manufacturing method reduce the assembly position tolerance to within 2 mm, reduce the amplitude of the range-extender assembly during driving, reduce the vehicle failure rate by 20%, and reduce the noise by 3 dB. The range-extender assembly manufactured by the method can be adapted to various vehicle models, improve the utilization rate of the vehicle space, increase the passenger compartment space by 170 mm, improve the system mode to 316 Hz, and improve the support strength of the range-extender assembly by 30%.

Description

[0001] This application claims priority to the Chinese Patent Application No. 202411277628.6, filed on September 12, 2024, and entitled "Vehicle", the content of which is incorporated herein by reference in its entirety. TECHNICAL FIELD

[0002] The present application relates to the technical field of vehicles, in particular to a range extended vehicle body and a manufacturing method thereof. BACKGROUND

[0003] With the improvement of environmental awareness and the pursuit of energy sustainability, the new energy vehicle market is booming. Range extended vehicles, with their unique advantages such as longer range, lower energy consumption, and excellent driving experience, are gradually emerging in the market and gaining more and more consumers' favor. In the key components of range extended vehicles, the range extender assembly plays a crucial role. As the core of vehicle power generation, it provides a solid guarantee for vehicle power supply, and its performance and stability directly affect 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 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 and the motor shell through a connecting plate, and the front end of the rotor support is connected with the end face of the engine output shaft. However, this scheme has the defect of a relatively long overall length of the motor, which not only leads to difficulties in arranging in the limited front engine compartment space of the vehicle, but also increases the overall 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 still has some shortcomings. Although this suspension structure considers vibration damping to some extent, due to its relatively complex design, it requires more parts to achieve the expected function, which not only increases the manufacturing cost, but also increases the difficulty of maintenance and repair in the later stage. Internationally, there are also some patent technologies related to range extender assemblies, such as the German patent with publication number DE102009057693A. This patent relates to a hybrid vehicle, and the connection method of the range extender and the vehicle chassis is relatively traditional, mainly using rigid connection. Although it ensures the stability of the connection, the vibration damping effect is poor. When the vehicle drives on bumpy roads, the vibration generated by the range extender will be directly transmitted to the vehicle body, not only reducing the ride comfort, but also possibly causing the related parts of the vehicle body to loosen and wear due to long-term vibration, affecting the reliability of the vehicle.

[0005] In summary, in the related prior art, the range-extending assembly in the range-extending vehicle is generally large in size, and the range-extender assembly is prone to large displacement or rotation during the driving of the vehicle, resulting in large vibration amplitude, which easily affects the vehicle body and cab, seriously affects the in-vehicle comfort, and may also cause long-term damage to the vehicle body structure, reducing the overall safety and durability of the vehicle. Therefore, how to optimize the mounting structure of the range-extender assembly to reduce its displacement, rotation and vibration during the driving of the vehicle, and maintain the stability and reliability of the range-extender assembly operation, has become a technical problem to be solved at present. SUMMARY

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

[0007] In order to achieve the above-mentioned purpose, the main technical scheme adopted by the present application includes:

[0008] The first aspect of the embodiment of the present application provides a range-extending vehicle body, which comprises a front engine compartment assembly, a floor assembly and a range-extender assembly. The first suspension and the second suspension are arranged on the front engine compartment assembly, and the first suspension and the second suspension are spaced apart in the left-right direction. The floor assembly is located behind the front engine compartment assembly, and the floor assembly comprises a floor body and a middle channel arranged on the floor body. The third suspension is arranged on the middle channel, and the third suspension is spaced apart from the first suspension and the second suspension in the front-rear direction, respectively. The third suspension is also spaced apart from the first suspension and the second suspension in the up-down direction, respectively. The range-extender assembly is fixed to the front engine compartment assembly and the floor assembly through the first suspension, the second suspension and the third suspension.

[0009] Since the first suspension, the second suspension and the third suspension can jointly form a triangular structure to fix the range-extender assembly, on the one hand, the design of the triangular suspension can make the three suspension points be arranged relatively uniformly around the range-extender assembly, forming a stable triangular support structure, which can effectively resist the torsion and vibration of the range-extender assembly from the driving process of the vehicle, thereby maintaining the stability and reliability of the range-extender assembly operation, improving the safety and reliability of the whole vehicle. On the other hand, the triangular suspension can also attenuate the vibration generated by the range-extender assembly during operation, reduce the influence of the vibration generated by the range-extender assembly on other components of the range-extending vehicle body, improve the noise of the range-extending vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range-extending vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0010] The third suspension is spaced apart from the first suspension and the second suspension in the up-down direction, which can improve the stability and maneuverability of the vehicle, and is conducive to inhibiting the longitudinal vibration of the range-extender assembly. Such a layout is conducive to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range-extender vehicle body and cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0011] In addition, the range-extender assembly in the embodiment of the present application can be finally integrated and installed on the front engine compartment assembly and the floor assembly after being assembled with the first suspension, the second suspension and the third suspension, so that the relative position of the installation point in the free state meets the composite position accuracy requirement, the position tolerance in the assembly process is reduced, and the position accuracy of the range-extender assembly is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range-extender assembly.

[0012] Optionally, the third suspension comprises 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 third suspension mounting bracket is provided on the middle passage, the third suspension mounting bracket is provided with a second mounting hole; and the second mounting hole and the first mounting hole are connected by a mounting bolt.

[0013] The first mounting hole on the inner core of the third suspension and the second mounting hole on the third suspension mounting bracket are connected by a mounting bolt, which has high connection strength, simple structure and is easy to implement. The elastic member arranged between the bushing seat and the inner core can adaptively reduce the jitter of the range-extender assembly during operation of the range-extender assembly, thereby playing a good buffering effect during vibration of the range-extender assembly, reducing the influence of vibration of the range-extender assembly on the range-extender vehicle body, improving the stability of the range-extender vehicle body, and avoiding collision between the inner core and the bushing seat during operation of the range-extender assembly, thereby reducing noise.

[0014] Optionally, the diameter of the first mounting hole is greater 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 greater than the diameter of the mounting bolt, so that the mounting bolt has a certain displacement in the first mounting hole in the up-down direction, so that after subsequent assembly of the range-extender assembly, the third suspension can be pulled down by the weight of the range-extender assembly itself, so that the mounting bolt is attached to the inner wall surface of the first mounting hole. In addition, the diameter of the first mounting hole being greater than the diameter of the mounting bolt also facilitates the matching installation of the mounting bolt, reduces the installation difficulty of the mounting bolt, and avoids improving the installation convenience.

[0016] After the range extender assembly is assembled, the third suspension can be pulled downward by the weight of the range extender assembly itself, so that the mounting bolt is attached to the inner wall surface of the first mounting hole, the structural stability is improved, and the third suspension can be located at a more accurate mounting position, the mounting precision of the third suspension is improved, and position interference between the third suspension and other components is avoided.

[0017] Optionally, the elastic member comprises 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 comprises a mounting cavity, and the inner core is mounted in the mounting cavity.

[0018] The inner core is arranged in the mounting cavity of the mounting portion, so that the connection stability of the inner core and the elastic member is improved. After the range extender assembly is assembled, the inner core is displaced by vibration of the range extender assembly, the connecting arm connected to the bushing seat and the mounting portion can provide a reverse pulling force and a buffering force for the inner core, the vibration of the range extender assembly is adaptively reduced during operation of the range extender assembly, and the vibration amplitude of the inner core and the range extender assembly is prevented from being too large, so that a good buffering effect is achieved during vibration of the range extender assembly.

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

[0020] The diameter of the first arc surface is relatively large, so that the inner core has sufficient volume to form the corresponding positioning hole and the mounting hole, the overall strength of the inner core is improved, the inner core is prevented from being damaged by stress, and the structural stability of the third suspension is improved. In addition, the diameter of the second arc surface is relatively small compared with the first arc surface, and the connecting arm is connected to the corresponding positions of the second arc surface and the connecting surface on the mounting portion, so that the volume of the connecting arm is increased, the buffering effect of the connecting arm is improved, the connection area between the connecting arm and the corresponding inner core on the mounting portion is increased, the stress of the inner core on the connecting arm is prevented from being too concentrated, the fatigue durability of the connecting arm is improved, and the service life of the elastic member is prolonged.

[0021] Optionally, the elastic member further comprises a first buffering portion and a second buffering portion, the first buffering portion forms a first gap between the connecting arm and the mounting portion, the second buffering portion forms a second gap between the connecting arm and the mounting portion, and the first gap and the second gap are arranged in a vertical direction.

[0022] The first gap and the second gap can provide a moving buffer space for the inner core to vibrate with the range extender assembly, further reduce the force transmitted by the inner core to the first buffer part and the second buffer part, improve the buffering effect, reduce the influence of the range extender assembly vibration on the range extended vehicle body, and improve the stability of the range extended vehicle body.

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

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

[0025] Optionally, the thickness of the second main plate is 4mm-5mm.

[0026] When the thickness of the second main plate is 4mm-5mm, the thickness of the second main plate is moderate, the volume is small, and it is not easy to interfere with other parts. Moreover, the second main plate has appropriate static stiffness and dynamic stiffness, which can ensure that the second main plate has good supporting and fixing effect on the range extender assembly, is not easy to resonate with the range extender assembly, reduces the influence on the range extended vehicle body and the vehicle cabin, and also reduces the risk of cracks or fractures of the second main plate, prolonging the service life. In addition, the second main plate also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the third suspension, and improve the comfort of driving and riding.

[0027] Optionally, the first suspension and the second suspension each comprise a suspension body, a connecting plate, a first main plate and a nut plate, one end of the suspension body is connected with the front engine compartment assembly, the other end is connected with the first main plate through the connecting plate, the nut plate is arranged on the first main plate and connected with the range extender through bolts.

[0028] The suspension body of the first suspension and the second suspension is connected with the first main plate through the connecting plate, which has simple structure, stable connection, and is easy to manufacture and assemble, and has low cost. The arrangement of the nut plate can avoid deformation of the first main plate when the first suspension and the second suspension are connected with the range extender assembly, thereby improving the structural stability of the first main plate. Moreover, the arrangement of the nut plate can also avoid the first main plate being too thick, thereby increasing the preparation cost and reducing the vibration isolation effect, and improving the NVH performance of the vehicle.

[0029] Optionally, the first main plate has a thickness of 4-5 mm; and / or the nut plate has a thickness of 3.5-4.5 mm; and / or the connecting plate has a thickness of 4-5 mm.

[0030] When the first main plate has a thickness of 4-5 mm, and / or the nut plate has a thickness of 3.5-4.5 mm, and / or the connecting plate has a thickness of 4-5 mm, the thickness of the first main plate, the nut plate and / or the connecting plate is moderate, the overall structure formed has a small volume and is not prone to interference with other components. Moreover, the first main plate, the nut plate and / or the connecting plate have appropriate static stiffness and dynamic stiffness, which can ensure that the overall structure formed by the first main plate, the nut plate and the 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 range extended vehicle body and the vehicle cabin, and also reduces the risk of cracking or breaking, thereby prolonging the service life. In addition, the overall structure formed by the first main plate, the nut plate and the connecting plate also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the first and second suspensions, thereby improving the comfort of driving and riding.

[0031] Optionally, the floor assembly further comprises a first floor cross beam extending in the left-right direction, and at least part of the first floor cross beam is fixedly attached to the lower side of the center tunnel, and the third suspension is arranged on the first floor cross beam.

[0032] The third suspension is arranged on the first floor cross beam, and the third suspension is connected with the range extender assembly, so that part of the gravity of the range extender assembly is borne by the first floor cross beam. Compared with directly arranging the third suspension on the floor body, arranging the third suspension on the first floor cross beam can greatly reduce the stress on the floor body. Moreover, the first floor cross beam can significantly increase the structural strength of the center tunnel, and the third suspension is directly connected with the first floor cross beam instead of being directly connected with the center tunnel, which can improve the installation stability of the range extender assembly. In addition, the first floor cross beam can buffer the vibration generated by the range extender assembly, thereby improving the overall shock absorption performance of the vehicle, and further greatly improving the use comfort of the user. For example, the first floor cross beam can increase the structural strength of the center tunnel by 20%, thereby ensuring the structural stability of the floor body.

[0033] Optionally, the first floor cross beam comprises a first body portion, a second body portion and a protruding portion connected between the first body portion and the second body portion, the protruding portion protrudes upward compared with the first body portion and the second body portion, wherein the protruding portion is fixedly attached to the lower side of the center tunnel, and the first body portion and the second body portion are both fixedly attached to the floor body; and the third suspension is arranged on the protruding portion.

[0034] The protrusion is fitted and fixed to the lower side of the central channel, and both the first and second body parts are fitted and fixed to the floor body. This reduces the single-point stress on the floor body, lowers the risk of stress concentration on the floor body, and improves the service life of the floor body, thereby improving the service life of the entire vehicle.

[0035] Optionally, both the first body portion and the second body portion include a first connecting portion and a second connecting portion, wherein the first connecting portion is connected between the protrusion and the second connecting portion.

[0036] Both the first body part and the second body part include a first connecting part and a second connecting part, so that the first connecting part, the second connecting part and the protrusion can be manufactured separately, which facilitates the replacement of the first connecting part, the second connecting part or the protrusion, increases the design freedom of the first floor crossbeam, and makes the first floor crossbeam applicable to different vehicle models, thus expanding the scope of use of the first floor crossbeam.

[0037] In addition, the structural strengths of the first connecting part, the second connecting part, and the protrusion can be set differently, so that the assembled first floor beam becomes a variable strength structure. This allows the structural strength of the first floor beam to 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 bent segment and a second bent segment that are bent relative to each other, the first bent segment being connected to the protrusion and the second bent segment being connected to the second connecting portion.

[0039] The first connecting part includes a first bent section and a second bent section that are relatively bent, which can increase the connection area between the first connecting part and the protrusion and the second connecting part, and increase the connection strength at the connection point of each component, thereby improving the structural stability of the first floor beam.

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

[0041] The structural strength of the protruding portion is higher than that of the first connecting portion and the second connecting portion, so that the support effect of the protruding portion on the middle channel can be improved, thereby ensuring the structural stability of the floor assembly. When the strength of the material of the protruding portion is higher than that of the first connecting portion and the second connecting portion, the structural strength of the protruding portion can be ensured to be higher than that of the first connecting portion and the second connecting portion, thereby improving the support effect of the protruding portion on the middle channel, and at the same time, the thickness of the protruding portion can be made thinner, thereby reducing the occupied space of the protruding portion and improving the space utilization of the middle channel. When the thickness of the protruding portion is greater than that of the first connecting portion and the second connecting portion, the structural strength of the protruding portion can be higher than that of the first connecting portion and the second connecting portion of the same material, so as to ensure the support effect of the protruding portion on the middle channel.

[0042] Optionally, the first floor cross beam is symmetrically arranged in the left-right direction.

[0043] The first floor cross beam is symmetrically arranged in the left-right direction, so that the modularity of the first floor cross beam can be realized, thereby enabling the first floor cross beam to move in the front-rear direction in the middle channel of the floor body, so that the first floor cross beam can adapt to different vehicle models, thereby improving the application range of the first floor cross beam and reducing the development cost.

[0044] Optionally, the floor assembly further comprises 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-rear direction, and the two ends of the first floor cross beam in the length direction are respectively connected with the first floor longitudinal beam and the second floor longitudinal beam.

[0045] The first floor cross beam is connected with the first floor longitudinal beam and the second floor longitudinal beam in the length direction (left-right direction), and the first floor longitudinal beam and the second floor longitudinal beam can support the first floor cross beam. In addition, the first floor cross beam can greatly improve the force transmission performance of the floor assembly, so that when the extended-range vehicle body is impacted by a force in the left-right direction, the force can be quickly transmitted out.

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

[0047] When the range extender assembly operates to generate vibration, the first floor cross beam 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 influence of the vibration generated when the range extender assembly operates on the extended-range vehicle body and improving the user's comfort.

[0048] Optionally, the front engine compartment assembly comprises a subframe, the subframe is connected with 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 floor longitudinal beam and the second floor longitudinal beam can support the subframe. Since the range-extender assembly is connected to the subframe through the first suspension and the second suspension respectively, and the subframe is connected to the first floor longitudinal beam and the second floor longitudinal beam, the range-extender assembly can be indirectly connected to the first floor longitudinal beam and the second floor longitudinal beam through the subframe, and the installation of the range-extender assembly is more free.

[0050] When the range-extender assembly operates to generate vibration, the subframe can disperse the vibration generated by the range-extender assembly through the first floor longitudinal beam and the second floor longitudinal beam, reduce the influence of the vibration generated by the range-extender assembly on the vehicle body of the range-extender vehicle when the range-extender assembly operates, and improve the use comfort of the user.

[0051] Optionally, the front engine compartment assembly further comprises a first front engine compartment longitudinal beam and a second front engine compartment longitudinal beam, the first front engine compartment longitudinal beam extends in the front-rear direction, the second front engine compartment longitudinal beam extends in the front-rear direction, and the second front engine compartment longitudinal beam is spaced apart from the first front engine compartment longitudinal beam in the left-right direction, wherein the subframe is further connected to the first front engine compartment longitudinal beam and the second front engine compartment longitudinal beam respectively.

[0052] Therefore, the subframe not only connects the first floor longitudinal beam and the second floor longitudinal beam together, but also connects the first front engine compartment longitudinal beam and the second front engine compartment longitudinal beam together, so that the connection between the front engine compartment assembly and the floor assembly is more stable, and the installation stability of the range-extender assembly is improved.

[0053] The subframe is connected to the first front engine compartment longitudinal beam and the second front engine compartment longitudinal beam, and when the range-extender assembly operates to generate vibration, the subframe can disperse the vibration generated by the range-extender assembly through the first front engine compartment longitudinal beam and the second front engine compartment longitudinal beam, reduce the influence of the vibration generated by the range-extender assembly on the vehicle body of the range-extender vehicle when the range-extender assembly operates, and improve the use comfort of the user.

[0054] Optionally, the front engine compartment assembly defines a first accommodating space, the middle channel defines a second accommodating space, the second accommodating space communicates with the first accommodating space, the range-extender assembly comprises an engine and a generator, the engine is power-connected to the generator, the engine is located at the front side 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 arranged in the first accommodating space defined by the front engine compartment assembly, and another part of the range extender assembly is arranged in the second accommodating space defined by the middle channel, so that the front engine compartment assembly of a smaller vehicle model (a vehicle model with a smaller front end) can also be installed with the range extender assembly, thereby making the range extender assembly adapt to multiple vehicle models, expanding the application range of the range extender assembly, and improving the utilization rate of the interior space of the range extender vehicle body. For example, the structure can shorten the front suspension length of the range extender assembly in the front engine compartment assembly by more than 170 mm, that is, the passenger compartment space can be increased by more than 170 mm, thereby improving the utilization rate of the interior space of the range extender vehicle body.

[0056] Part of the engine is arranged in the first accommodating space, and another part of the engine and the generator are arranged in the second accommodating space. Since the first accommodating space is defined by the front engine compartment assembly and the second accommodating space is arranged below the floor assembly, when the engine is in operation, it will generate a lot of noise and vibration. Compared with arranging the entire engine in the second accommodating space, arranging part of the engine in the first accommodating space can obviously greatly reduce the influence of the vibration and noise generated by the engine on the passengers, and greatly improve the comfort of the vehicle.

[0057] Optionally, the range extender assembly further comprises a generator controller, the generator comprises a first shell, the generator controller comprises a second shell, and the range extender assembly further comprises a third shell. The third shell and the first shell jointly define a first space for accommodating the rotor, and the third shell and the second shell jointly define a second space for accommodating electrical components. The upper side of the first shell is provided with a recessed portion recessed upward, and 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 in the front-rear direction.

[0058] The first shell, the second shell, and the third shell jointly define an accommodating space for accommodating 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 shell is provided with a recessed portion recessed upward, and a plurality of reinforcing ribs are arranged on the recessed portion. This can improve the system modal of the vehicle and improve the support strength of the range extender assembly. For example, the system modal of the vehicle can be improved to 316 Hz, and the support strength of the range extender assembly can be improved by 30%, thereby improving the overall performance of the vehicle.

[0060] Optionally, the range extender assembly comprises an engine and a generator. The engine is in power connection with the generator. The engine is located at the front side of the generator. The engine has a first power output shaft, and the generator has a first power input shaft. The first power output shaft and the second power input shaft are parallel and extend in the front-rear direction.

[0061] That is, the engine and the generator are installed in the front-rear direction, thereby reducing the occupation of the front engine compartment assembly in the left-right direction.

[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 extending in parallel and in the front-rear direction, so that the power of the engine can be transmitted to the generator more smoothly, the overall modal of the vehicle system is improved, and the generation of the vibration of the range extender assembly is reduced.

[0063] The range extended vehicle body further comprises a speed increaser, the speed increaser comprising a first driving gear and a first driven gear meshing with each other, the first driving gear being connected with the engine in power, and the first driven gear being connected with the generator in power, wherein the rotation axis of the first driving gear and the rotation axis of the second driving gear are spaced apart in the up-down direction.

[0064] The rotation axis of the first driving gear and the rotation axis of the first driven gear are spaced apart in the up-down direction, so that the space of the engine compartment in the up-down direction can be fully utilized, the space occupation of the speed increaser in the left-right direction of the engine compartment is reduced, and the range extender assembly can be more compact in the front-rear direction, the length of the range extender assembly in the front-rear direction can be significantly reduced, and the application range of the range extender assembly can be expanded, so that the range extender assembly can be installed on a vehicle with a smaller front engine compartment assembly.

[0065] The second aspect of the embodiment of the present application provides a manufacturing method of a range extended vehicle body, which is used to manufacture the range extended vehicle body described in any one of the above embodiments, and the manufacturing method of the range extended vehicle body comprises:

[0066] Manufacturing a front engine compartment assembly;

[0067] Manufacturing a floor assembly, the floor assembly being provided with a middle channel;

[0068] Connecting the floor assembly with the front engine compartment assembly;

[0069] Connecting a first suspension, a second suspension and a third suspension with 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] Connecting the first suspension and the second suspension with the front engine compartment assembly, and connecting the third suspension with the middle channel.

[0071] Since the first suspension, the second suspension and the third suspension jointly constitute a triangular structure to fix the range extender assembly, on the one hand, the design of the triangular suspension can make the three suspension points be more uniformly arranged around the range extender assembly to form a stable triangular support structure, which can effectively resist the torsion and vibration of the range extender assembly from various directions during the driving of the vehicle, thereby maintaining the stability and reliability of the operation of the range extender assembly, improving the safety and reliability of the vehicle, on the other hand, the triangular suspension can also attenuate the vibration of the range extender assembly during operation, reduce the influence of the vibration of the range extender assembly on other components of the range extended vehicle body, improve the noise of the range extended vehicle body and improve the use comfort of the vehicle. For example, the noise of the range extended vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0072] The third suspension is spaced apart from the first suspension and the second suspension in the up-down direction, that is, the first suspension and the second suspension can be below the third suspension, and the third suspension is above the first suspension and the second suspension, that is, the first suspension and the second suspension are arranged below the range extender assembly, and the third suspension is arranged above the range extender assembly, which improves the stability and maneuverability of the vehicle, and the mass center distribution of the range extender assembly is more reasonable. Moreover, the suspensions at different positions can be optimally arranged for vibration in different directions, the first suspension and the second suspension are arranged below the range extender assembly, which is beneficial to the vibration of the range extender assembly in the horizontal direction and the vertical direction, and the third suspension is arranged above the range extender assembly, which is beneficial to suppressing the longitudinal vibration of the range extender assembly. Such a layout is beneficial to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range extended vehicle body and the cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0073] In addition, the range extender assembly in the embodiment of the present application can be assembled with the first suspension, the second suspension and the third suspension, and finally integrated and installed on the front engine compartment assembly and the floor assembly, so that the relative positions of the mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process is reduced, and the position accuracy of the range extender assembly is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

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

[0075] A floor blank is manufactured;

[0076] The floor blank is subjected to draw forming processing to form the floor body and the middle channel, and a storage convex is formed on the middle channel;

[0077] The floor blank is shaped to form an arc-shaped corner of the junction of the middle channel and the floor body by pressing down the storage bump.

[0078] The floor blank is drawn to form the floor body and the middle channel, and the storage bump is formed on the middle channel. When the floor blank after the drawing forming is shaped, the storage bump can be pressed down to form an arc-shaped corner of the junction of the middle channel and the floor body, thereby forming a floor assembly to meet the use requirements of the extended-range automobile body. The manufacturing process is simple and facilitates mass production of the floor assembly. By forming the storage bump on the middle channel during the drawing forming of the floor blank, a stepped structure similar to the middle channel side wall can be formed, thereby ensuring the overall depth of the middle channel while avoiding a steep draft angle, improving the forming conditions, reducing the risk of cracking in the middle channel during the drawing forming process, improving the production yield, and saving manufacturing costs. For example, the production yield of the middle channel can be improved to 100%, avoiding cracking in the middle channel during the drawing forming process.

[0079] Optionally, the arc length of the storage bump is equal to the arc length of the corresponding arc-shaped corner.

[0080] When the arc length of the storage bump is equal to the arc length of the corresponding arc-shaped corner, the overall thickness of the floor assembly can be uniform when the storage bump is pressed down to form an arc-shaped corner of the junction of the middle channel and the floor body, avoiding the risk of wrinkles, folds or cracking in the arc-shaped corner, further improving the production yield and saving manufacturing costs. BRIEF DESCRIPTION OF DRAWINGS

[0081] In order to more clearly illustrate the specific embodiments of the present application or the technical solutions in the prior art, the following will briefly introduce the drawings needed to be used in the description of the specific embodiments or the prior art. Obviously, the drawings described below are some embodiments of the present application, and those skilled in the art can also obtain other drawings according to these drawings without creative labor.

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

[0083] Figure 2 Structure schematic diagram of the extended-range automobile body provided by an embodiment of the present application;

[0084] Figure 3 Structure schematic diagram of the front engine compartment assembly provided by an embodiment of the present application;

[0085] Figure 4 Structure schematic diagram of the front engine compartment assembly provided by an embodiment of the present application but excluding the range extender assembly;

[0086] Figure 5 A bottom view of the front cabin assembly according to an embodiment of the present application;

[0087] Figure 6 A structural schematic diagram of the front cabin assembly but excluding the range extender assembly and the floor assembly according to an embodiment of the present application;

[0088] Figure 7 A partial structural schematic diagram of the range extended vehicle body according to an embodiment of the present application;

[0089] Figure 8 A schematic diagram of the partial structure of the range extended vehicle body according to an embodiment of the present application from another perspective;

[0090] Figure 9 A side view of the third suspension according to an embodiment of the present application;

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

[0092] Figure 11 A structural schematic diagram of the third suspension from another angle according to an embodiment of the present application;

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

[0094] Figure 13 A partial structural schematic diagram of the first suspension according to an embodiment of the present application;

[0095] Figure 14 A partial structural schematic diagram of the second suspension according to an embodiment of the present application;

[0096] Figure 15 The first suspension and the second suspension are shown;

[0097] Figure 16 The third suspension is shown;

[0098] Figure 17 The middle channel structure is shown;

[0099] Figure 18 A partial structural schematic diagram of the first floor cross beam according to an embodiment of the present application;

[0100] Figure 19 A partial structural schematic diagram of the range extended vehicle body according to another embodiment of the present application;

[0101] Figure 20 An exploded schematic diagram of the partial structure of the first floor cross beam according to an embodiment of the present application;

[0102] Figure 21 A partial structural schematic view of a floor assembly according to an embodiment of the present application;

[0103] Figure 22 A structural schematic view of a range extender assembly according to an embodiment of the present application;

[0104] Figure 23 An enlarged view of a range extender assembly according to an embodiment of the present application;

[0105] Figure 24 An enlarged view of a range extender assembly according to an embodiment of the present application;

[0106] Figure 25 A third suspension is shown;

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

[0108] Figure 27 A flow chart of a manufacturing method of a floor assembly according to an embodiment of the present application;

[0109] Figure 28 A drawing forming process state of a floor blank in a manufacturing process of a floor assembly according to an embodiment of the present application;

[0110] Figure 29 A shaping process state of a floor blank in a manufacturing process of a floor assembly according to an embodiment of the present application.

[0111]

BRIEF DESCRIPTION OF DRAWINGS

[0112] range extender assembly 130'; front suspension 116'; rear suspension 127'; vehicle body 100; front engine compartment assembly 110; first accommodating space 110A; first suspension 111; second suspension 112; subframe 113; first front engine compartment longitudinal beam 114; second front engine compartment longitudinal beam 115; suspension body 116; connecting plate 117; first main plate 118; nut plate 119; floor assembly 120; floor body 121; middle channel 122; lower side surface 1220; second accommodating space 122A; 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 arc surface 1233B; second arc surface 1233C; connecting surface 1233D; first gap 1234; second gap 1235; second main plate 1236; mounting surface 1236A; first floor cross beam 124; first body portion 124A; second body portion 124B; protruding portion 124C; first connecting portion 1241; first bent section 1241A; second bent section 1241B; second connecting portion 1242; first floor longitudinal beam 125; second floor longitudinal beam 126; third suspension mounting bracket 127; second mounting hole 127A; mounting bolt 128; arc-shaped 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 concave die 301; drawing convex die 302; shaping concave die 401; shaping convex die 402; floor blank 500; storage convex bump 501; front-rear direction X; left-right direction Y; up-down direction Z. DETAILED DESCRIPTION

[0113] In order to make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present 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 their derivatives as used in the specification of the present application and the claims and the above summary are meant as being inclusive rather than exclusive in that they allow for the possibility of additional or supplemental elements, both individually and collectively. The terms "first", "second", and the like, as used in the specification of the present application and the claims, do not imply a particular order but are used for the purpose of nomenclature.

[0115] In the present application, the phrase "embodiment" means that the specific features, structures or characteristics described in connection with the embodiment can be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment to other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described in the present application can be combined with other embodiments.

[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 broadly, for example, it can be fixed connection, or detachable connection, or integral connection; it can be directly connected, or indirectly connected through an intermediate medium, or it 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] In the present application, the term "and / or" is only a description of the association relationship between the associated objects, which means that there can be three kinds of 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] In the present application, "multiple" 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 to 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 increasingly 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 the extended range vehicle, the extended range assembly is usually installed by multiple suspension devices.

[0121] Figure 1 Part of the structure of the extended range vehicle body in the related art is shown in a specific embodiment. As shown in Figure 1 The front suspension 116' and the rear suspension 127' are both located below the extended range assembly 130', which is supported by the front suspension 116' and the rear suspension 127' to form a lower supporting installation structure. However, due to the large volume of the extended range assembly 130' in the extended range vehicle, the inertia of the extended range assembly 130' is prone to cause large displacement or rotation during driving, resulting in large vibration amplitude, which is prone to affect the extended range vehicle body and the cab.

[0122] Therefore, the present application provides an extended range vehicle body and a manufacturing method thereof, which reduces the vibration amplitude of the extended range assembly during driving, reduces the influence of the vibration of the extended range assembly on the extended range vehicle body and the cab, and improves the noise of the extended range vehicle body. The vehicle disclosed in the embodiments of the present application can include a microcar with a short extended range vehicle body and a small number of seats (two or four seats), as well as a small car, a compact car, a medium car, a medium-large car, etc.

[0123] The front engine compartment assembly disclosed in the embodiments of the present application can include a first accommodating space, a first suspension, a second suspension, a subframe, a first front engine compartment longitudinal beam, and a second front engine compartment longitudinal beam, etc.

[0124] The floor assembly disclosed in the embodiments of the present application can include a floor body, a middle channel, a second accommodating space, a third suspension, a first floor transverse beam, a first floor longitudinal beam, and a second floor longitudinal beam.

[0125] The following embodiments are described with reference to an extended range vehicle body of an embodiment of the present application for convenience of description.

[0126] Please refer to Figures 2 to 8 , Figure 2 the structure diagram of the extended range vehicle body provided by an embodiment of the present application; Figure 3 the structure diagram of the front engine compartment assembly 110 provided by an embodiment of the present application; Figure 4 the structure diagram of the front engine compartment assembly 110 provided by an embodiment of the present application but without the extended range assembly 130; Figure 5 the bottom view of the front engine compartment assembly 110 provided by an embodiment of the present application;

[0127] Figure 6A structural schematic diagram of the front cabin assembly 110 provided by an embodiment of the present application, but 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 suspension 111, the second suspension 112, and the third suspension 123 is shown; Figure 8 A structural schematic diagram of the range extender assembly 130 and the first suspension 111, the second suspension 112, and the third suspension 123 is shown.

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

[0129] The range-extending vehicle body 100 includes 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 includes a floor body 121 and a center tunnel 122 provided on the floor body 121, and the center tunnel 122 is provided with a third suspension 123, which is spaced apart from the first suspension 111 and the second suspension 112 in the front-rear direction X and is also spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z. 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.

[0130] The first suspension 111 and the second suspension 112 are provided on the front cabin assembly 110, and the third suspension 123 is provided on the center tunnel 122. The first suspension 111 and the second suspension 112 are arranged in a first accommodation space 110A, and the third suspension 123 is arranged in a second accommodation 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-rear direction X. The first suspension 111, the second suspension 112, and the third suspension 123 jointly form a triangular structure, and 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] Since the first suspension 111, the second suspension 112 and the third suspension 123 jointly constitute a triangular structure to fix the range extender assembly 130, on the one hand, the design of the triangular suspension can make the three suspension points be more evenly arranged around the range extender assembly 130, forming a stable triangular support structure, which can effectively resist the torsion and vibration of the range extender assembly 130 from various aspects during the driving of the vehicle, thereby maintaining the stability and reliability of the operation of the range extender assembly 130, improving the safety and reliability of the vehicle, on the other hand, the triangular suspension can also attenuate the vibration generated by the range extender assembly 130 during operation, reduce the influence of the vibration generated by the range extender assembly 130 on other components of the range extended vehicle body 100, improve the noise of the range extended vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range extended vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0132] Fixing the range extender assembly 130 on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension can also realize the independent installation and disassembly of the range extender assembly 130, which is convenient for maintenance and replacement when the range extender assembly 130 fails, which is also conducive to improving the manufacturing and assembly efficiency of the vehicle. Moreover, the layout of the triangular suspension is relatively compact, which can maximize the use of the space inside the range extended vehicle body 100, reduce the interference with other components, and improve the space utilization of the vehicle.

[0133] Fixing the range extender assembly 130 on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension is also conducive to reducing the loss of power during transmission, improving the power output efficiency of the range extender assembly 130, and further improving 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, that is, the first suspension 111 and the second suspension 112 can 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, which improves the stability and maneuverability of the vehicle, and the mass center of the range extender assembly 130 is more reasonable. Moreover, the suspensions at different positions can be optimized for vibration in different directions. The first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, which is conducive to horizontal and vertical vibration of the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, which is conducive to suppressing longitudinal vibration of the range extender assembly 130. Such a layout is conducive to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range extender vehicle body and cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0135] In addition, the range extender assembly 130 in the embodiment of the application can be assembled with the first suspension 111, the second suspension 112, and the third suspension 123, and finally integrated and installed on the front engine compartment assembly 110 and the floor assembly 120, so that the relative positions of the three mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process can be reduced, and the position accuracy of the range extender assembly 130 is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

[0136] In a specific embodiment, the displacement of the range extender assembly 130 in the front-rear direction X is generally required to be between -15 mm and 15 mm, and the rotation angle in the left-right direction Y is generally required to be between -1.5° and 1.5°. As described above, the range extender assembly 130 is arranged below the first suspension 111 and the second suspension 112, and the third suspension 123 is arranged above the range extender assembly 130, which is conducive to reducing the influence of vibration on the range extender vehicle body and the cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. Figure 1In the related art shown, when the vehicle is in the process of front or rear collision with acceleration between-11g and 11g, 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 is in the process of forward or backward movement with acceleration between-3g and 3g, 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, the maximum positive displacement and the maximum negative displacement of the range extender assembly 130' when the vehicle is in the process of front or rear collision with acceleration between-11g and 11g both exceed the required range of-15mm to 15mm, and the maximum positive rotation angle and the maximum negative rotation angle of the range extender assembly 130' both exceed the required range of-1.5° to 1.5°, so the displacement is large, causing a large vibration amplitude, which is easy to affect the range extender vehicle body and cab, and the noise is also large.

[0137] However, when the vehicle is in the process of front or rear collision with acceleration between-11g and 11g, 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 is in the process of forward or backward movement with acceleration between-3g and 3g, 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 application effectively reduces the displacement of the range extender assembly 130 in the front and rear direction X and the rotation angle in the left and right direction Y, that is, the maximum displacement when the vehicle is in the process of front or rear collision, forward movement or backward movement is between-15mm and 15mm, and the maximum rotation angle is between-1.5° and 1.5°, so the vibration amplitude of the range extender assembly 130 can be reduced, the influence of the vibration generated by the range extender assembly 130 on other parts of the range extender vehicle body can be reduced, the use comfort of the vehicle can be improved, and the noise of the range extender vehicle body can be improved. For example, the noise of the range extender vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle can be improved.

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

[0139] In some embodiments, the first suspension 111, the second suspension 112, and the third suspension 123 can be configured as rubber suspensions, hydraulic suspensions, semi-active suspensions, and active suspensions. Rubber suspensions are made of natural or synthetic rubber and possess excellent physical and mechanical properties, noise reduction, vibration isolation, and buffering capabilities. Rubber suspensions can be classified structurally into bushing-type suspensions, block-shaped rubber suspensions, and wedge-shaped rubber suspensions, etc. Hydraulic suspensions have decoupling discs / membranes and flow channels forming inertial channels arranged internally, absorbing and attenuating vibrations through the flow of liquid. Hydraulic suspensions can be classified structurally into cylindrical hydraulic suspensions and trapezoidal hydraulic suspensions. Pressure mounts have excellent dynamic characteristics and can adapt to vibration reduction and noise reduction requirements at different frequencies and amplitudes; semi-active mounts combine an electronic control unit, a solenoid valve, and a mount body with a movable valve (which can be a rubber mount or a hydraulic resistance mount), and dynamically adjust the stiffness and damping of the mount by controlling the flow of fluid to adapt to different operating conditions; active mounts generate dynamic force through actuators to counteract engine vibration, achieving more precise vibration control. Active mounts consist of passive mounts (rubber mounts or hydraulic resistance mounts), vibration sensors, controllers, and actuators, and 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 element 1232, and an inner core 1233. The elastic element 1232 is installed inside the bushing seat 1231, and the inner core 1233 is installed inside the elastic element 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 by a mounting bolt 128.

[0142] In the embodiment, the first mounting hole 1233A on the inner core 1233 of the third suspension 123 is connected with the second mounting hole 127A on the third suspension mounting bracket 127 through the mounting bolt 128, which has high connection strength, simple structure and is easy to realize. The elastic member 1232 arranged between the bushing seat 1231 and the inner core 1233 can adaptively reduce the jitter of the range extender assembly 130 during the working process of the range extender assembly 130, thereby playing a good buffering effect during the vibration of the range extender assembly 130, reducing the influence of the vibration of the range extender assembly 130 on the range-extended vehicle body, improving the stability of the range-extended vehicle body, and avoiding the collision between the inner core 1233 and the bushing seat 1231 during the working process of the range extender assembly 130, thereby reducing the noise.

[0143] In a specific embodiment, as shown in Figure 8 and Figure 9 , 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 the embodiment, after the range extender assembly 130 is assembled, the range extender assembly 130 can be used to pull the third suspension 123 downward by its own weight, so that the mounting bolt 128 is attached to the inner wall surface of the first mounting hole 1233A, thereby improving the structural stability, and the third suspension 123 can be driven to a more accurate mounting position, thereby improving the mounting accuracy of the third suspension 123 and avoiding position 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-down direction Z can be between 0.5mm and 1.5mm, for example, it can be 0.5mm, 0.8mm, 1mm, 1.2mm, 1.5mm, etc., so as to avoid that the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A is too large, causing the mounting bolt 128 to be unable to match the installation, or the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A is too small, which cannot improve the mounting accuracy of the third suspension 123.

[0146] Further, as shown in Figure 8 and Figure 9 , the diameter of the first mounting hole 1233A is greater 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 comprises a first arc surface 1233B, a second arc surface 1233C, and a connecting surface 1233D connected between the first arc surface 1233B and the second arc surface 1233C. The diameter of the first arc surface 1233B is greater than the diameter of the second arc surface 1233C, and the connecting arm 1232B is connected to the corresponding positions of the second arc surface 1233C and the connecting surface 1233D on the mounting portion 1232A.

[0152] In this embodiment, the diameter of the first arc surface 1233B is relatively large, so that the inner core 1233 has sufficient volume to form corresponding positioning holes and mounting holes, improves the overall strength of the inner core 1233, avoids damage to the inner core 1233 under stress, and improves the structural stability of the third suspension 123. In addition, the diameter of the second arc surface 1233C is relatively small compared to the first arc surface 1233B, and the connecting arm 1232B is connected to the corresponding positions of the second arc surface 1233C and the connecting surface 1233D on the mounting portion 1232A, which can improve the volume of the connecting arm 1232B, thereby improving the buffering effect of the connecting arm 1232B, and can improve the connection area of the connecting arm 1232B and the corresponding inner core 1233 on the mounting portion 1232A, thereby avoiding excessive stress concentration of the inner core 1233 on the connecting arm 1232B, improving the fatigue durability of the connecting arm 1232B, and prolonging the service life of the elastic member 1232.

[0153] In this embodiment, the diameter of the first arc surface 1233B is relatively large, so that the inner core 1233 has sufficient volume to form corresponding positioning holes and mounting holes, improves the overall strength of the inner core 1233, avoids damage to the inner core 1233 under stress, and improves the structural stability of the third suspension 123. In addition, the diameter of the second arc surface 1233C is relatively small compared to the first arc surface 1233B, and the connecting arm 1232B is connected to the corresponding positions of the second arc surface 1233C and the connecting surface 1233D on the mounting portion 1232A, which can improve the volume of the connecting arm 1232B, thereby improving the buffering effect of the connecting arm 1232B, and can improve the connection area of the connecting arm 1232B and the corresponding inner core 1233 on the mounting portion 1232A, thereby avoiding excessive stress concentration of the inner core 1233 on the connecting arm 1232B, improving the fatigue durability of the connecting arm 1232B, and prolonging the service life of the elastic member 1232.

[0154] In one specific embodiment, as shown in Figure 9 The elastic member 1232 further comprises a first buffer portion 1232C and a second buffer portion 1232D, the first buffer portion 1232C forms a first gap 1234 between the connecting arm 1232B and the mounting portion 1232A, and the second buffer portion 1232D forms a second gap 1235 between the connecting arm 1232B and the mounting portion 1232A. The first gap 1234 and the second gap 1235 are spaced apart in the up-down direction Z.

[0155] In the embodiment, the first gap 1234 and the second gap 1235 can provide a moving buffer space for the inner core 1233 to vibrate with the range extender assembly 130, further reduce the force transmitted by the inner core 1233 to the first buffer part 1232C and the second buffer part 1232D, improve the buffering effect, reduce the influence of the vibration of the range extender assembly 130 on the range extended vehicle body, and improve the stability of the range extended vehicle body.

[0156] Figure 11 A structural schematic view of the third suspension 123 at another angle is shown. In one specific embodiment, as shown in Figure 8 the third suspension 123 further includes a second main plate 1236, one end of the second main plate 1236 is connected with the bushing seat 1231, and the other end of the second main plate 1236 is provided with a mounting surface 1236A connected with the range extender assembly 130.

[0157] In the embodiment, as shown in Figure 8 and Figure 11 the mounting surface 1236A on the second main plate 1236 is connected and fixed with the range extender assembly 130, which can increase the connection area of the third suspension 123 and the range extender assembly 130, thereby improving the connection strength of 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] In the embodiment, the mounting surface 1236A can be provided as a symmetrical structure on the second main plate 1236 to improve the contact area of the mounting surface 1236A and the range extender assembly 130, thereby improving the connection strength. In other embodiments, the second main plate 1236 can be symmetrically arranged on opposite sides of the bushing seat 1231 to improve the design freedom of the third suspension 123, so that the third suspension 123 can adapt to the range extended vehicle body structure of different vehicles.

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

[0160] In one specific embodiment, as shown in Figure 11 the thickness of the second main plate 1236 is 4mm-5mm. For example, the thickness of the second main plate 1236 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc., which can be set according to actual needs, which is not limited herein.

[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 the embodiment, the suspension body 116 of the first suspension 111 and the second suspension 112 is connected with the first main plate 118 through the connecting plate 117, which is simple in structure, stable in connection, easy to manufacture and assemble, and low in cost. The setting of the nut plate 119 can avoid the deformation of the first main plate 118 when the first suspension 111 and the second suspension 112 are connected with the range extender assembly 130, thereby improving the structural stability of the first main plate 118. In addition, the setting of the nut plate 119 can also avoid the increase of the thickness of the first main plate 118, thereby reducing the preparation cost and the vibration isolation effect, and improving the NVH performance of the vehicle.

[0165] In the embodiment, the suspension body 116 of the first suspension 111 and the second suspension 112 is connected with the first main plate 118 through the connecting plate 117, which is simple in structure, stable in connection, easy to manufacture and assemble, and low in cost. The setting of the nut plate 119 can avoid the deformation of the first main plate 118 when the first suspension 111 and the second suspension 112 are connected with the range extender assembly 130, thereby improving the structural stability of the first main plate 118. In addition, the setting of the nut plate 119 can also avoid the increase of the thickness of the first main plate 118, thereby reducing the preparation cost and the vibration isolation effect, and improving the NVH performance of the vehicle.

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

[0167] Figure 13 Fig. 1 shows a partial structural schematic diagram of the first suspension, Figure 14 Fig. 2 shows a partial structural schematic diagram of the second suspension. As shown in Figure 13 and Figure 14 In one embodiment, the thickness of the first main plate 118 is 4mm-5mm, and / or the thickness of the nut plate 119 is 3.5mm-4.5mm, and / or the thickness of the connecting plate 117 is 4mm-5mm. For example, the thickness of the first main plate 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 thickness of the first main plate 118, the nut plate 119 and the connecting plate 117 can be set according to actual requirements, which is not limited herein.

[0168] The thickness of the first main plate 118, the nut plate 119 and / or the connecting plate 117 is too thin, and the static stiffness and dynamic stiffness are low, which is easy to produce bending and torsion, reduces the support and fixing effect of the first suspension 111 and the second suspension 112 on the range extender assembly 130, and is also easy to produce vibration noise. The thickness of the first main plate 118, the nut plate 119 and / or the connecting plate 117 is too thin, which is also easy to produce resonance with the range extender assembly 130, reduces the risk of cracking or breaking of the parts, reduces the service life, and is also easy to affect the range extender automobile body and the car body, reduces the comfort of driving and riding. If the thickness of the first main plate 118, the nut plate 119 and / or the connecting plate 117 is too thick, the static stiffness and dynamic stiffness are too high, which is easy to reduce the isolation effect of high-frequency vibration on the range extender assembly 130. And the thickness is too thick, which is easy to increase the volume of the parts, which is easy to interfere with other parts in the range extender automobile body 100, and also increases 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 plate 118 is 4mm-5mm, and / or the thickness of the nut plate 119 is 3.5mm-4.5mm, and / or the thickness of the connecting plate 117 is 4mm-5mm, the thickness of the first main plate 118, the nut plate 119 and / or the connecting plate 117 is moderate, and the overall structure is small in size and is not easy to interfere with other parts. And the first main plate 118, the nut plate 119 and / or the connecting plate 117 have appropriate static stiffness and dynamic stiffness, which can ensure that the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 has good support and fixing effect on the range extender assembly 130, and is not easy to produce resonance with the range extender assembly 130, reduces the influence on the range extender automobile body and the car body, and also reduces the risk of cracking or breaking, prolongs the service life. In addition, the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 also has 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 comfort of driving and riding.

[0170] In a specific embodiment, the maximum speed of the engine in the range extender assembly 130 is N = 6000 RPM, and the second order natural frequency f2 of the engine is calculated as f2 = N / 60*2 = 200 Hz, and the fourth order natural frequency f4 is calculated as f4 = N / 60*4 = 400 Hz. According to the noise, vibration, harshness (NVH) performance requirements of the vehicle, it is usually required that the first order modal natural frequency F of the suspension bracket is greater than or equal to 500 Hz. In the embodiment of the present application, the thickness of the first main plate 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 plate 118, the nut plate 119 and the connecting plate 117 is 633 Hz; the thickness of the first main plate 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, and the first order modal natural frequency of the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 is 572 Hz; the thickness of the second main plate 1236 of the third suspension 123 is 4.5 mm, and the first order modal natural frequency thereof is 594 Hz. In the present application, the first suspension 111, the second suspension 112 and the third suspension 123 can all meet the NVH performance requirements of the vehicle, avoid resonance with the range extender assembly 130, improve the NVH performance of the vehicle, and at the same time reduce the risk of crack or fracture failure of the first suspension 111, the second suspension 112 and the third suspension 123.

[0171] Figure 15 The first suspension 111 and the second suspension 112 are shown; Figure 16 The third suspension 123 is shown; Figure 17 The first suspension 111 is shown. Figure 8 The middle 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 In the present embodiment, the floor assembly 120 further comprises a first floor cross beam 124 extending along the left-right direction Y, and at least a portion of the first floor cross beam 124 is fixedly attached to the lower side 1220 of the middle channel 122, and the third suspension 123 is arranged on the first floor cross beam 124.

[0173] The first floor cross beam 124 extends along the left-right direction Y, and at least part of the first floor cross beam 124 is fixedly attached to the lower side 1220 of the middle channel 122, that is, at least part of the first floor cross beam 124 is attached to the floor body 121, and the first floor cross beam 124 can partially support the floor body 121. Since the floor body 121 bears a relatively large force, the first floor cross beam 124 supports the floor body 121, effectively sharing the force of the floor body 121, avoiding single-point force on the floor body 121, and improving the service life and use efficiency of the floor body 121.

[0174] The third suspension 123 is arranged on the first floor cross beam 124, and the third suspension 123 is connected to the range extender assembly 130, so that part of the gravity of the range extender assembly 130 is borne by the first floor cross beam 124. Compared with directly arranging the third suspension 123 on the floor body 121, arranging the third suspension 123 on the first floor cross beam 124 can greatly reduce the force borne by the floor body 121. Moreover, the first floor cross beam 124 can significantly increase the structural strength of the middle channel 122, and the third suspension 123 is directly connected to the first floor cross beam 124 instead of being connected to the middle channel 122, which can improve the mounting stability of the range extender assembly 130. In addition, the first floor cross beam 124 can buffer the vibration generated by the range extender assembly 130, thereby improving the overall shock absorption performance of the vehicle, and further greatly improving the user's use comfort. For example, the first floor cross beam 124 can increase the structural strength of the middle channel 122 by 20%, ensuring the structural stability of the floor body 121.

[0175] In some embodiments, the first floor cross beam 124 can be made of a material with high strength. For example, the material of the first floor cross beam 124 can be made of steel or aluminum alloy. Steel has high strength and rigidity, which can provide a stable support structure for the range extended vehicle body. This high strength and rigidity ensures that the first floor cross beam 124 does not deform under various loads. Moreover, steel is easy to shape and weld during processing, which ensures a firm connection between the first floor cross beam 124 and other components of the range extended vehicle body 100. Steel also has good durability and fatigue resistance, allowing the first floor cross beam 124 to maintain stable performance over a long period of use. Aluminum alloy has excellent lightweight performance and high rigidity. Compared with steel, using aluminum alloy for the first floor cross beam 124 can significantly reduce the weight of the range extended vehicle body, thereby improving fuel economy and reducing environmental impact. In addition, aluminum alloy also has good corrosion resistance, which can maintain a long service life in harsh environments.

[0176] In some embodiments, the first floor cross beam 124 and the third suspension 123 can be connected by bolts, which is a detachable connection method. When the equipment needs to be repaired, replaced or adjusted, it can be easily separated by disassembling the bolts without damaging the connecting parts themselves. Moreover, the bolts themselves are made of high-strength materials such as carbon steel, stainless steel or alloy steel, etc., which can withstand large tensile and shear forces. In addition, by selecting the appropriate bolt diameter, length and thread type, its carrying capacity and durability can be further enhanced to ensure the long-term stability of the connection. Bolt connection has high precision because the tightness and stability of the connection can be ensured by controlling the tightening torque and pre-tightening force of the bolts. This precision helps to reduce looseness and vibration, improving the efficiency and reliability of the equipment. Bolt connection usually does not require complex installation tools or equipment, and can be completed with basic tools such as wrenches and screwdrivers. At the same time, due to the detachability of the bolts, the maintenance and repair of the equipment become 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 In this embodiment, the floor assembly 120 further includes a first floor longitudinal beam 125 and a second floor longitudinal beam 126, both of which are arranged on the floor body 121 and extend in the front-rear direction X. The first floor cross beam 124 is connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126 at both ends in the length direction, respectively.

[0178] The first floor longitudinal beam 125 and the second floor longitudinal beam 126 are spaced apart in the left-right direction Y. Both the first floor longitudinal beam 125 and the second floor longitudinal beam 126 are arranged on the floor body 121 and extend in the front-rear direction X. Both the first floor longitudinal beam 125 and the second floor longitudinal beam 126 have a certain supporting effect on the floor body 121, reducing the single-point stress condition of the floor body 121 and reducing the risk of stress concentration of the floor body 121.

[0179] The first floor cross beam 124 is connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126 in the length direction (left-right direction Y), and the first floor longitudinal beam 125 and the second floor longitudinal beam 126 can support the first floor cross beam 124. In addition, the first floor cross beam 124 can also greatly improve the force transmission performance of the floor assembly 120, so that when the vehicle is impacted by the force in the left-right direction Y, the force can be quickly transmitted out.

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

[0181] Since the range extender assembly 130 is connected with the first floor cross beam 124 through the third suspension 123, and the first floor cross beam 124 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, when the range extender assembly 130 generates vibration during operation, the first floor cross beam 124 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 influence of the vibration generated by the range extender assembly 130 during operation on the vehicle and improving the user's comfort.

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

[0183] The front engine compartment assembly 110 includes a subframe 113, the subframe 113 is arranged at the front of the range extended vehicle body, the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, the first suspension 111 and the second suspension 112 are arranged on the subframe 113, the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 in the length direction (left-right direction Y), and the first floor longitudinal beam 125 and the second floor longitudinal beam 126 can support the subframe 113. Since the range extender assembly 130 is connected with the subframe 113 through the first suspension 111 and the second suspension 112 respectively, and the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, the range extender assembly 130 can be indirectly connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 through the subframe 113, and the installation of the range extender assembly 130 is more free.

[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 influence of the vibration generated by the range extender assembly 130 during operation on the vehicle and improving the user's 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 engine compartment assembly 110 further includes a first front engine compartment longitudinal beam 114 and a second front engine compartment longitudinal beam 115. The first front engine compartment longitudinal beam 114 extends in the longitudinal direction X, and the second front engine compartment longitudinal beam 115 extends in the longitudinal direction X. The second front engine compartment longitudinal beam 115 and the first front engine compartment longitudinal beam 114 are spaced apart in the left-right direction Y. The subframe 113 is also connected to the first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 respectively.

[0186] Therefore, 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 engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 together, thereby making the connection between the front engine compartment 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 engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115. The first suspension 111 and the second suspension 112 are mounted on the subframe 113. The subframe 113 is connected to the first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 in the longitudinal direction (left-right direction Y). The first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 can provide support for the subframe 113. Since the range extender assembly 130 is connected to the subframe 113 via the first mount 111 and the second mount 112 respectively, and the subframe 113 is connected to the first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115, when the range extender assembly 130 vibrates during operation, the subframe 113 can disperse the vibration generated by the range extender assembly 130 through the first front engine compartment longitudinal beam 114 and the second front engine compartment 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 the embodiment, the first floor cross beam 124 comprises a first body part 124A, a second body part 124B, and a protruding part 124C connected between the first body part 124A and the second body part 124B, wherein the protruding part 124C protrudes upward compared with the first body part 124A and the second body part 124B, and the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, and the first body part 124A and the second body part 124B are fixedly attached to the floor body 121.

[0189] The first body part 124A and the second body part 124B are spaced apart in the left-right direction Y, and the first body part 124A and the second body part 124B are connected by the protruding part 124C, wherein the protruding part 124C protrudes upward compared with the first body part 124A and the second body part 124B, and the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, that is, the protruding part 124C can play a supporting role with the lower side 1220 of the middle channel 122, and the first body part 124A and the second body part 124B can be attached to the floor body 121, and the first body part 124A and the second body part 124B can support the floor body 121, and the first body part 124A and the second body part 124B can be connected to the first floor longitudinal beam 125 and the second floor longitudinal beam 126 respectively.

[0190] Specifically, the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, and the first body part 124A and the second body part 124B are fixedly attached to the floor body 121, which can reduce the single-point stress condition of the floor body 121, reduce the risk of stress concentration of the floor body 121, improve the service life of the floor body 121, and further improve the service life of the whole vehicle.

[0191] Figure 18 The first floor cross beam 124 is shown in a specific embodiment, wherein the third suspension mounting bracket 127 is arranged on the protruding part 124C, so that the third suspension 123 is arranged on the protruding part 124C through the third suspension mounting bracket 127.

[0192] Figure 19 The part structure of the extended-range vehicle body in a specific embodiment is shown in a specific embodiment; Figure 20 The exploded view of the part structure of the first floor cross beam 124 in a specific embodiment is shown.

[0193] As 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 material strength of the protruding portion 124C is higher than that of the first connecting portion 1241 and the second connecting portion 1242, or the thickness of the protruding portion 124C is greater than that of the first connecting portion 1241 and the second connecting portion 1242.

[0200] In this embodiment, the structural strength of the protruding portion 124C is higher than that of the first connecting portion 1241 and the second connecting portion 1242, thereby improving the supporting effect of the protruding portion 124C on the central passage 122 and ensuring the structural stability of the floor assembly 120. When the material strength of the protruding portion 124C is higher than that of the first connecting portion 1241 and the second connecting portion 1242, the structural strength of the protruding portion 124C can be ensured to be higher than that of the first connecting portion 1241 and the second connecting portion 1242, thereby improving the supporting effect of the protruding portion 124C on the central passage 122, and the thickness of the protruding portion 124C can be made thinner, thereby reducing the occupied space of the protruding portion 124C and improving the space utilization of the central passage 122. When the thickness of the protruding portion 124C is greater than that of the first connecting portion 1241 and the second connecting portion 1242, the structural strength of the protruding portion 124C can be higher than that of the first connecting portion 1241 and the second connecting portion 1242 made of the same material, thereby ensuring the supporting effect of the protruding portion 124C on the central passage 122.

[0201] The end of the second connecting portion 1242 of the first body portion 124A away from the first connecting portion 1241 is connected with the first floor longitudinal beam 125, and the end of the second connecting portion 1242 of the second body portion 124B away from the first connecting portion 1241 is connected with the second floor longitudinal beam 126, thereby improving the connecting strength of the first floor transverse beam 124 with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 and the connecting stability of the first floor transverse beam 124 on the floor body 121, thereby ensuring the supporting effect of the first floor transverse beam 124 on the floor body 1.

[0202] In a specific embodiment, as shown in Figure 19 and Figure 20 The first connecting portion 1241 includes a first bending segment 1241A and a second bending segment 1241B that are relatively bent, the first bending segment 1241A is connected with the protruding portion 124C, and the second bending segment 1241B is connected with the second connecting portion 1242.

[0203] In this embodiment, the first connecting portion 1241 includes a first bending segment 1241A and a second bending segment 1241B that are relatively bent, thereby improving the connecting area of the first connecting portion 1241 with the protruding portion 124C and the second connecting portion 1242 and improving the connecting strength of the connecting portions of the components, thereby improving the structural stability of the first floor transverse beam 124.

[0204] The manufacturing materials and processes of the first connecting part 1241, the second connecting part 1242, or the protrusion 124C can be different. Specifically, they can be formed separately by an expansion process using tubular materials, or by die casting, or by other methods, so that different parts of the first floor beam 124 can be matched with the floor body 121 or the third suspension mounting bracket 127 in different ways, further improving the design freedom of the range-extended vehicle body. The specific design can be set according to actual needs, and no restrictions are imposed here.

[0205] Figure 21 A partial structural schematic diagram of the floor assembly 120 in one specific embodiment is shown.

[0206] In one specific embodiment, such as Figure 19 and Figure 20 As shown, the first floor beam 124 is symmetrically arranged in the left-right Y direction.

[0207] In this embodiment, as Figures 19 to 21 As shown, the first floor crossbeam 124 is symmetrically arranged in the left-right direction Y, which can realize the modularity of the first floor crossbeam 124. This allows the first floor crossbeam 124 to move in the front-back direction X in the central channel 122 on the floor body 121, so that the first floor crossbeam 124 can adapt to different vehicle models, improve the applicability of the first floor crossbeam 124, and reduce development costs.

[0208] The first connecting part 1241 of the first body part 124A and the second body part 124B can be set to be the same, thereby realizing the commonality of the first connecting part 1241 in the first body part 124A and the second body part 124B. This allows the first connecting part 1241 to be manufactured in a unified manner, reducing the number of manufacturing molds and further reducing manufacturing costs.

[0209] In some other embodiments, the first connecting portion 1241, the second connecting portion 1242, and the protrusion 124C of the first floor beam 124 can also be integrally formed to facilitate mass production of the first floor beam 124 and save manufacturing costs. Specifically, it can be integrally formed using a tubular material through an expansion process, or it can be integrally formed by die casting. Of course, it can also be prepared and formed by other methods. The specific method can be set according to actual needs and is not limited here.

[0210] In related technologies, because the range extender assembly in a range-extended vehicle integrates a generator, an electric motor, and a generator controller, the range extender assembly is relatively large and requires a lot of space in the front engine compartment. As a result, the space limited by the front engine compartment assembly must be large enough to meet the installation requirements of the range extender.

[0211] In this embodiment, please refer toFigure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 15 , Figure 16 and Figure 17 As shown, the range-extended vehicle body 100 includes a front engine compartment assembly 110, a floor assembly 120, and a range extender assembly 130. The front engine compartment assembly 110 defines a first accommodating space 110A. The floor assembly 120 is located behind the front engine compartment assembly 110. The floor assembly 120 includes a floor body 121 and a central channel 122 disposed in the floor body 121. The central channel 122 defines a second accommodating space 122A, which communicates with the first accommodating space 110A. 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. Since a portion of the range extender assembly 130 is located in the first accommodating space 110A and another portion of the range extender assembly 130 is located in the second accommodating space 122A, the space under the front engine compartment assembly 110 and the floor assembly 120 of the range extender vehicle body 100 can be fully utilized, so even models with a smaller front engine compartment can be designed as range extenders.

[0212] The front engine compartment assembly 110 defines a first accommodating space 110A. The floor assembly 120 is located behind the front engine compartment assembly 110, that is, the floor assembly 120 is located behind the first accommodating space 110A. The floor assembly 120 includes a floor body 121 and a central channel 122 disposed in the floor body 121. Due to the complex structural limitations of the range-extended vehicle body 100 itself, the cross-sectional shape of the floor body 121 along the front-rear direction X can be approximately Z-shaped, thus forming a central channel 122 below 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 receiving space 110A, and another portion of the range extender assembly 130 is disposed in the second receiving space 122A, that is, the range extender assembly 130 spans the first receiving space 110A and the second receiving space 122A.

[0213] For a vehicle with a smaller front engine assembly 110, a smaller front engine assembly 110 design means less air resistance when air flows through this area, which helps to improve the aerodynamic performance of the vehicle. This design can reduce the wind resistance of the vehicle when driving, thereby improving fuel economy and reducing energy loss during driving. A smaller front engine assembly 110 can also reduce air turbulence, making the vehicle more stable at high speeds and helping to improve top speed and acceleration performance. Moreover, a smaller front engine assembly 110 means that less material and components are needed to build, which helps to reduce the curb weight of the vehicle and effectively reduce the overall manufacturing cost of the vehicle.

[0214] The front engine assembly 110 is smaller, and in general, the first accommodation space 110A is also smaller, while the volume of the range extender assembly 130 is relatively large. By arranging part of the range extender assembly 130 in the first accommodation space 110A and another part of the range extender assembly 130 in the second accommodation space 122A, the volume occupied by the range extender assembly 130 in the first accommodation space 110A can be significantly reduced, so that a vehicle with a smaller front engine assembly 110 (smaller first accommodation space 110A) can also install a larger range extender assembly 130, expanding the range of vehicle models suitable for the range extender assembly 130. For example, for a vehicle with a larger front engine assembly 110 and a larger first accommodation space 110A, arranging part of the range extender assembly 130 in the first accommodation space 110A and another part of the range extender assembly 130 extending into the second accommodation space 122A can also effectively save the space occupancy rate of the front engine assembly 110, and thus the remaining space inside the front engine assembly 110 can be used to set up storage space or other components, which can significantly improve the space utilization inside the vehicle, further expanding the passenger's use space and improving the passenger's use comfort. Moreover, by arranging the range extender assembly 130 in the first accommodation space 110A and the second accommodation space 122A, compared to arranging the range extender assembly 130 separately in the first accommodation space 110A or the second accommodation space 122A, the range extender assembly is arranged in a larger accommodation space, which is beneficial to dissipate the heat generated by the range extender assembly 130 during operation, thereby improving the service life and working 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 engine assembly 110 by more than 170 mm, i.e., the passenger compartment space can be increased by more than 170 mm, improving the space utilization inside the range extended vehicle body.

[0216] In some embodiments, the range extended vehicle body further comprises a fuel tank 190, which is arranged 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 structure schematic view of the range-extender assembly 130 provided by an embodiment of the present application; Figure 23 a local enlarged view of the range-extender assembly 130 provided by an embodiment of the present application; Figure 24 a local enlarged view of the range-extender assembly 130 provided by 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 with the generator 132 and is arranged in front of the generator 132, the generator 132 is connected with the generator controller 133 and is arranged in front of the generator controller 133. The first shell 140, the second shell 141 and the third shell 142 are all arranged on the range extender assembly 130, the first shell 140 and the third shell 142 define a first space accommodating the stator and rotor (the generator 132), and the second shell 141 and the third shell 142 jointly define a second space accommodating electrical components.

[0225] Specifically, the first shell 140, the second shell 141 and the third shell 142 jointly define an accommodation space accommodating 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 the embodiment, the upper side of the first shell 140 is provided with a recessed portion 140A recessed upward, and the first shell 140 is further 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 in the front-rear direction X.

[0227] The upper side of the first shell 140 is provided with a recessed portion 140A recessed upward, and the first shell 140 is further 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 in the front-rear direction X.

[0228] In some embodiments, the third shell 142 can be further provided with four mounting holes 200, and the third suspension 123 is fixedly connected with 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 the embodiment, the range extender assembly includes the engine 131 and the 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, the engine 131 has a first power output shaft 131A, the generator 132 has a first power input shaft 132A, the first power output shaft 131A is parallel with the second power input shaft and both extend in the front-rear direction X.

[0230] The engine 131 and the generator 132 are power-connected, the engine 131 is located at the front side of the generator 132, the first power output shaft 131A of the engine 131 is connected with the first power input shaft 132A of the motor 180, the first power output shaft 131A of the engine 131 rotates to drive 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-rear direction X, thereby reducing the occupation of the left-right direction Y space of the front engine 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-rear direction X, which can make the power of the engine 131 more smoothly transmitted to the generator 132, improve the overall modal of the vehicle system, and reduce the generation of the vibration of the range extender assembly 130.

[0233] Please refer to Figures 22 to 25 In the embodiment, the range extended vehicle body further comprises a speed increaser 150, the speed increaser 150 comprises a first driving gear 151 and a first driven gear 152 which are engaged with each other, the first driving gear 151 is power-connected with the engine 131, the first driven gear 152 is power-connected with the generator 132, and 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 power-connected with the engine 131, the first driven gear 152 of the speed increaser 150 is power-connected with the generator 132, that is, the power output by the engine 131 is transmitted to the first driving gear 151 of the speed increaser 150, the first driving gear 151 transmits power to the first driven gear 152, and then the first driven gear 152 transmits power to the generator 132. For example, the number of teeth of the first driving gear 151 is generally less than that of the driven gear.

[0235] The rotation axis of the first driving gear 151 is spaced apart from the rotation axis of the first driven gear 152 in the up-down direction Z, which can make full use of the space of the front engine assembly 110 in the up-down direction Z, reduce the space occupation of the speed increaser 150 in the left-right direction Y of the front engine assembly 110, and of course make the range extender assembly 130 more compact in the front-rear direction X, which can significantly reduce the length of the range extender assembly 130 in the front-rear direction X, and further expand the application range of the range extender assembly 130, so that the range extender assembly 130 can also be installed on the vehicle model with a smaller front engine assembly 110.

[0236] As Figure 26As shown, the application also provides a manufacturing method of the range extended vehicle body, for manufacturing the range extended vehicle body 100 in any of the above embodiments, the manufacturing method of the range extended vehicle body 100 comprises:

[0237] Step S1, manufacturing the front engine compartment assembly 110.

[0238] In this step, the front engine compartment assembly 110 disclosed in the embodiments of the application can include a first accommodating space, a first suspension, a second suspension, a subframe, a first front engine compartment longitudinal beam, and a second front engine compartment longitudinal beam, etc.

[0239] Step S2, manufacturing the floor assembly 120, as shown in Figure 21 The floor assembly 120 is provided with a middle channel 122.

[0240] In this step, the floor assembly 120 disclosed in the embodiments of the application can also include a floor body, a second accommodating space, a third suspension, a first floor transverse beam, a first floor longitudinal beam, and a second floor longitudinal beam, etc.

[0241] Step S3, as shown in Figures 2 to 5 Connecting the floor assembly 120 and the front engine compartment assembly 110.

[0242] In this step, the floor assembly 120 and the front engine compartment assembly 110 are connected to form a whole, so that the subsequent range extender assembly 130 is connected to the whole structure formed by the floor assembly 120 and the front engine compartment assembly 110 through the first suspension 111, the second suspension 112, and the third suspension 123.

[0243] Step S4, as shown in Figure 2 , Figure 7 , Figure 8 Connecting the first suspension 111, the second suspension 112, and the third suspension 123 with 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 with the range extender assembly 130 to form a whole, so that the subsequent range extender assembly 130 is connected to the whole structure formed by the floor assembly 120 and the front engine compartment assembly 110 through the first suspension 111, the second suspension 112, and the third suspension 123.

[0245] Step S5, as shown in Figure 2 , Figure 3 , Figure 5 , Figure 6 , Figure 16 , and Figure 17The first suspension 111 and the second suspension 112 are connected to the front engine compartment 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 overall structure formed by the floor assembly 120 and the front engine compartment assembly 110 through the first suspension 111, the second suspension 112, and the third suspension 123, so that the range extender assembly 130 is mounted on the floor assembly 120 and the front engine compartment assembly 110.

[0247] In this embodiment, the first suspension 111 and the second suspension 112 are arranged on the front engine compartment assembly 110, and the third suspension 123 is arranged 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-rear direction X. The first suspension 111, the second suspension 112, and the third suspension 123 jointly form a triangular structure, and the range extender assembly 130 is fixed to the front engine compartment assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112, and the third suspension 123.

[0248] Since the first suspension 111, the second suspension 112, and the third suspension 123 jointly form a triangular structure to fix the range extender assembly 130, on the one hand, the design of the triangular suspension can make the three suspension points be arranged relatively uniformly around the range extender assembly 130, forming a stable triangular support structure. This can effectively resist the torsion and vibration of the range extender assembly 130 from various sources during vehicle driving, thereby maintaining the stability and reliability of the range extender assembly 130 operation, improving the safety and reliability of the vehicle, and on the other hand, the triangular suspension can also attenuate the vibration generated by the range extender assembly 130 during operation, reduce the influence of the vibration generated by the range extender assembly 130 on other components of the range extended vehicle body 100, improve the noise of the range extended vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range extended vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle can be improved.

[0249] Fixing the range extender assembly 130 to the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension can also realize the independent installation and disassembly of the range extender assembly 130, which is convenient for maintenance and replacement of the range extender assembly 130 when it fails, and is also conducive to improving the manufacturing and assembly efficiency of the vehicle. Moreover, the layout of the triangular suspension is relatively compact, which can maximize the use of the space inside the range extended vehicle body 100, reduce the interference with other components, and improve the space utilization of the vehicle.

[0250] The range extender assembly 130 is fixed on the front cabin assembly 110 and the floor assembly 120 through the triangular suspension, which is also conducive to reducing the loss of power during transmission, improving the power output efficiency of the range extender assembly 130, and further improving 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, that is, the first suspension 111 and the second suspension 112 can 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, which improves the stability and maneuverability of the vehicle, and the mass center distribution of the range extender assembly 130 is more reasonable. Moreover, the suspensions at different positions can be optimally arranged for vibrations in different directions, the first suspension 111 and the second suspension 112 arranged below the range extender assembly 130 are conducive to horizontal and vertical vibrations of the range extender assembly 130, and the third suspension 123 arranged above the range extender assembly 130 is conducive to suppressing the longitudinal vibration of the range extender assembly 130. Such a layout is conducive to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range extender vehicle body and cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the failure probability of the vehicle can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0252] In addition, the range extender assembly 130 in the embodiment of the present application can be assembled with the first suspension 111, the second suspension 112, and the third suspension 123, and finally integrated and installed on the front cabin assembly 110 and the floor assembly 120, so that the relative positions of the three mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process is reduced, and the position accuracy of the range extender assembly 130 is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

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

[0254] Step S21, manufacturing a floor blank 500.

[0255] In this step, the floor blank 500 can be a flat plate structure or an approximately flat plate structure with a certain thickness.

[0256] Step S22, as shown in Figure 28 the floor blank 500 is subjected to drawing forming processing to form the floor body 121 and the middle channel 122, and the storage convex 501 is formed on the middle channel 122.

[0257] In this step, the floor blank 500 can be placed between the drawing concave die 301 and the drawing convex die 302, and the floor blank 500 is pressed by the drawing concave die 301 and the drawing convex die 302 to draw the floor body 121 and the middle channel 122, and form the storage convex bump 501 on the middle channel 122.

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

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

[0260] The middle channel 122 of the floor assembly 120 is relatively deep in order to accommodate part of the range extender assembly 130, so that during the manufacturing of the floor assembly 120, the middle channel 122 is prone to cracking due to the excessive depth of the drawing and the steep draft angle during the drawing of the floor blank, resulting in a low production yield.

[0261] In this embodiment, as shown in Figure 28 and Figure 29 , the floor blank 500 is drawn and formed to form the floor body 121 and the middle channel 122, and the storage convex bump 501 is formed on the middle channel 122. When the floor blank 500 after the drawing forming process is shaped, the storage convex bump 501 can be pressed to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121, thereby forming the floor assembly 120 to meet the use requirements of the range extended vehicle body 100.

[0262] This manufacturing process is simple and facilitates mass production of the floor assembly 120. By forming the storage convex bump 501 on the middle channel 122 during the drawing and forming process of the floor blank 500, a stepped structure similar to the stepped structure is formed at the sidewall of the middle channel 122, thereby ensuring the overall depth of the middle channel 122 while avoiding the steep draft angle, improving the forming conditions, reducing the risk of cracking at the middle channel 122 during the drawing and forming process, improving the production yield, and saving the manufacturing cost. For example, the production yield at the middle channel 122 can be improved to 100%, avoiding cracking at the middle channel 122 during the drawing and forming process.

[0263] In this embodiment, as shown in Figure 28As shown, the protrusion and the recess structure corresponding to the position of the storage protrusion 501 on the drawing punch 302 and the drawing die 301 can be set to make the floor blank 500 form the storage protrusion 501 on the middle channel 122 during the drawing process.

[0264] In addition, as shown, Figure 29 As shown, the protrusion and the recess structure corresponding to the position of the storage protrusion 501 on the drawing punch 302 and the drawing die 301 can be set to make the floor blank 500 form the storage protrusion 501 on the middle channel 122 during the drawing process.

[0265] Wherein, between step S22 and step S23, the floor assembly 120 can also include trimming, punching, trimming, flanging and other steps, which can be set according to actual needs, and is not limited here.

[0266] In a specific embodiment, as shown in Figure 28 and Figure 29 As shown, the arc length of the storage protrusion 501 is equal to or approximately equal to the arc length of the corresponding arc-shaped corner 129. If the arc length of the storage protrusion 501 is too long, when the storage protrusion 501 is pressed to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121, there is a risk of wrinkling and stacking at the arc-shaped corner 129. If the arc length of the storage protrusion 501 is too short, when the storage protrusion 501 is pressed to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121, the thickness of the formed arc-shaped corner 129 is too thin, which reduces the structural strength, or the arc-shaped corner 129 is prone to cracking.

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

[0268] Preferably, the arc length of the storage convex 501 is equal to the arc length of the corresponding arc-shaped corner 129, so as to ensure that the overall thickness of the formed floor assembly is uniform, and to avoid wrinkles or cracks in the arc-shaped corner 129.

[0269] It should also be noted that the terms "comprising", "containing", or any other similar term means inclusion of non-exclusive inclusion, so that a process, method, article or apparatus that includes a list of elements does not only include those elements, but also includes other elements not explicitly listed, or inherent to such process, method, article or apparatus. Without more limitations, the element defined by the phrase "comprising a" does not exclude the presence of additional identical elements in the process, method, article or apparatus that includes the element.

[0270] Each of the embodiments in the specification is described in a progressive manner, and the same or similar parts between the embodiments can be referred to each other. Each embodiment focuses on the difference from other embodiments. In particular, for the system embodiments, since they are basically similar to the method embodiments, the description is relatively simple, and the relevant parts can be referred to the part of the method embodiments.

[0271] The above only describes the embodiments of the present application and is not intended to limit the present application. Those skilled in the art can make various modifications and changes to the present application. Any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the scope of the claims of the present application.

[0272] Although the embodiments of the present application are described in conjunction with the drawings, those skilled in the art can make various modifications and changes without departing from the spirit and scope of the present application, and such modifications and changes fall within the scope defined by the appended claims.

Claims

1. A range extended vehicle body, characterized by, The application relates to 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 which are spaced apart in the left-right direction. The floor assembly is located behind the front cabin assembly and comprises a floor body and a middle channel provided on the floor body. The middle channel is provided with a third suspension which is spaced apart from the first suspension and the second suspension in the front-rear direction and is also spaced apart from the first suspension and the second suspension in the up-down direction. The floor assembly further comprises a first floor crossbeam extending in the left-right direction, and at least part of the first floor crossbeam is fixed to the lower side of the middle channel.

2. The range extended vehicle body of claim 1, wherein, 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. The first suspension and the second suspension are arranged below the range extender assembly, and the third suspension is arranged above the range extender assembly.

3. The range extended vehicle body of claim 2, wherein, The third suspension comprises a bushing seat, an elastic element and an inner core. The elastic element is arranged in the bushing seat, and the inner core is arranged in the elastic element.

4. The extended-range automotive vehicle body of claim 2, wherein, The inner core is provided with a first mounting hole.

5. The extended-range automotive vehicle body of claim 4, wherein, The middle channel is provided with a third suspension mounting bracket which is provided with a second mounting hole. The first mounting hole is connected with the second mounting hole through a mounting bolt.

6. The extended-range automotive vehicle body of claim 4, wherein, The diameter of the first mounting hole is larger than the diameter of the mounting bolt. The center position of the first mounting hole is lower than the center position of the second mounting hole in the up-down direction. The elastic element comprises a mounting part and a connecting arm.

7. The range extended vehicle body of claim 2, wherein, One end of the connecting arm is connected with the inner wall of the bushing seat, and the other end of the connecting arm is connected with the mounting part.

8. The range extended vehicle body of claim 7, wherein, The mounting part comprises a mounting cavity, and the inner core is arranged in the mounting cavity.

9. The extended-range automotive vehicle body of any one of claims 1-8, wherein, The inner core comprises a first arc surface, a second arc surface and a connecting surface connected between the first arc surface and the second arc surface. The diameter of the first arc surface is larger than the diameter of the second arc surface. The connecting arm is connected with the corresponding positions of the second arc surface and the connecting surface of the mounting part. The elastic element further comprises a first buffer part and a second buffer part. The first buffer part forms a first gap between the connecting arm and the mounting part. The second buffer part forms a second gap between the connecting arm and the mounting part. The first gap and the second gap are arranged in the up-down direction. The third suspension further comprises a second main plate. One end of the second main plate is connected with the bushing seat, and the other end of the second main plate is provided with a mounting surface connected with the range extender assembly. The thickness of the second main plate is 4mm-5mm. The first suspension and the second suspension each comprise a suspension body, a connecting plate, a first main plate and a nut plate. One end of the suspension body is connected with the front cabin assembly, and the other end of the suspension body is connected with the first main plate through the connecting plate. The nut plate is arranged on the first main plate and is connected with the range extender assembly through a bolt.

10. The range extended vehicle body of claim 9, wherein, The thickness of the first main plate is 4mm-5mm; and / or, The thickness of the nut plate is 3.5mm-4.5mm; and / or, The thickness of the connecting plate is 4mm-5mm.

11. The range extended vehicle body of claim 1, wherein, The first floor beam comprises a first body part, a second body part, and a protruding part connected between the first body part and the second body part, the protruding part protruding upward compared with the first body part and the second body part; The protruding part is fixedly attached to the lower side of the middle channel, and the first body part and the second body part are fixedly attached to the floor body; the third suspension is arranged on the protruding part.

12. The range extended car body of claim 11, wherein, The first body part and the second body part each comprise a first connecting part and a second connecting part, and the first connecting part is connected between the protruding part and the second connecting part.

13. The range extended car body of claim 12, wherein, The material strength of the protruding part is higher than that of the first connecting part and the second connecting part; Alternatively, the thickness of the protruding part is greater than that of the first connecting part and the second connecting part.

14. The extended-range automotive vehicle body of claim 1, wherein, The first floor beam is symmetrically arranged in the left-right direction.

15. The vehicle body according to any one of claims 1 to 8, characterized by The front engine compartment assembly defines a first accommodating space, and the middle channel defines a second accommodating space, which is in communication with the first accommodating space; The range extender assembly comprises an engine and a generator, the engine is in power connection with the generator, and the engine is located at the front side of the generator; 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.

16. The range extended car body of claim 15, wherein, The range extender assembly further comprises a generator controller, the generator comprises a first shell, and the motor controller comprises a second shell; The range extender assembly further comprises a third shell, the first shell and the third shell jointly define a first space for accommodating a rotor, and the third shell and the second shell jointly define a second space for accommodating electrical components; The upper side of the first shell is provided with a recessed part 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 part and extends in the front-rear direction.

17. A method of manufacturing a range extended vehicle body, characterized by, The manufacturing method of the vehicle body as claimed in any one of claims 1-16 comprises: manufacturing a front engine compartment assembly; manufacturing a floor assembly, which is provided with a middle channel; connecting the floor assembly with the front engine compartment assembly; connecting a first suspension, a second suspension, and a third suspension with a 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; connecting the first suspension and the second suspension with the front engine compartment assembly, and connecting the third suspension with the middle channel.

18. The method of manufacturing an extended-range automotive vehicle body of claim 17, wherein, The manufacturing of the floor assembly specifically comprises: manufacturing a floor blank; performing drawing forming processing on the floor blank to form the floor body and the middle channel, and forming a storage protrusion on the middle channel; performing shaping processing on the floor blank to press down the storage protrusion to form an arc-shaped corner at the connection between the middle channel and the floor body.

19. The method of manufacturing an extended-range automotive vehicle body of claim 18, wherein, The arc length of the storage convex is equal to the arc length of the corresponding arc-shaped corner.

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