Speed-increasing generator structure and speed-increasing method

Abstract

This invention relates to the field of range extender generator technology, specifically proposing a speed-increasing generator structure and method. The speed-increasing generator structure includes: a drive unit, a sun gear, a ring gear disk, and planetary gears. A drive shaft is mounted on the drive unit. The sun gear is located on one side of the drive unit and coaxially connected to the drive shaft. The ring gear disk is located on one side of the drive unit, between the drive unit and the ring gear disk, and has internal teeth circumferentially arranged around the drive shaft at its outer edge. Multiple planetary gears are rotatably mounted on one side of the drive unit, respectively meshing with the internal teeth of the ring gear disk and the sun gear. The ring gear disk is connected to the engine shaft. The planetary gears achieve speed increase, improving the generator's speed and power density. Simultaneously, by placing the sun gear and planetary gears on one side of the drive unit, integrating them with the drive unit, the longitudinal arrangement space of the generator is reduced, thus meeting the assembly requirements of a direct-drive connection while ensuring performance.

Description

Technical Field

[0001] This invention belongs to the field of range extender generator technology, and specifically relates to a speed-increasing generator structure and speed-increasing method. Background Technology

[0002] Range extender generators are a core component of new energy vehicles, enabling cost control while ensuring performance requirements.

[0003] The main configuration of existing range extender generators is direct drive connection. However, direct drive connection range extender generators result in limited installation space inside the vehicle, making it difficult to install the appropriate gear speed-increasing mechanism. Consequently, the generator speed is limited by the engine speed, failing to meet the basic output requirements for high speeds. To meet the basic output requirements for high speeds, the only way is to increase the generator torque, which places a greater load on the generator rotor, thereby increasing the generator's operating costs. Summary of the Invention

[0004] To address the above problems, this invention proposes a speed-increasing generator structure, comprising:

[0005] The drive unit is provided with a drive shaft;

[0006] A sun gear is disposed on one side of the drive unit and coaxially connected to one end of the drive shaft;

[0007] A gear ring disk is disposed on one side of the drive unit, such that the sun gear is located between the drive unit and the gear ring disk, and the outer edge of the gear ring disk near the drive unit is provided with internal teeth circumferentially around the drive shaft;

[0008] The planetary gears are provided in multiples, and the multiple planetary gears are rotatably disposed on one side of the drive unit. The multiple planetary gears are evenly arranged around the drive shaft in the circumference, so that each planetary gear meshes with the internal teeth of the gear ring disk and the sun gear respectively.

[0009] The gear ring disk is connected to the engine shaft on the side away from the drive unit.

[0010] In some specific embodiments, the driving unit includes:

[0011] The housing has a mounting groove on one side;

[0012] The drive shaft is rotatably disposed within the housing, and one end of the drive shaft passes through the mounting groove;

[0013] A rotor, which is located inside the housing and is sleeved on the outer periphery of the drive shaft;

[0014] A stator is circumferentially disposed on the inner wall of the housing around the drive shaft.

[0015] In some specific embodiments, the mounting groove is provided with multiple connecting shafts, each of which corresponds to a planetary gear. The planetary gears are rotatably mounted on the corresponding connecting shafts via connecting bearings.

[0016] In some specific embodiments, the gear ring disk is disposed on the mounting groove, such that the inner teeth of the gear ring disk are embedded in the outer edge of the mounting groove.

[0017] In some specific embodiments, one end of the drive shaft located inside the housing is rotatably connected to the inner wall of the housing via a first fixed bearing;

[0018] One end of the drive shaft located in the mounting groove is rotatably connected to the side wall of the gear ring disk via a second bearing.

[0019] In some specific embodiments, the gear ring disk has a stepped structure on the side away from the drive shaft, and the stepped structure is embedded and connected to the engine shaft.

[0020] In some specific embodiments, an elastic pad is provided between the end face of the drive shaft located in the mounting groove and the side wall of the gear ring disk.

[0021] In some specific embodiments, a first ring plate is provided circumferentially around the drive shaft on one side of the rotor, and the first ring plate is connected to the drive shaft through a first limiting sleeve;

[0022] A second ring plate is circumferentially embedded on one side of the sun gear around the drive shaft, and the second ring plate is connected to the drive shaft through a second limiting sleeve.

[0023] In some specific embodiments, the rotor and the drive shaft are integrated into a single structure.

[0024] A speed-increasing method based on the same concept, employing a speed-increasing generator structure as described in any of the above specific embodiments, includes the following steps:

[0025] The drive shaft of the drive unit operates to drive the sun gear to rotate circumferentially around the drive shaft;

[0026] The rotation of the sun gear simultaneously drives multiple planet gears to rotate circumferentially, thereby causing the gear ring to rotate circumferentially around the drive shaft.

[0027] Speed ​​is achieved by rotating the engine shaft through the rotation of the gear ring disc.

[0028] Compared with existing technologies, the speed-increasing generator structure of the present invention has at least the following advantages: The drive shaft of the drive unit drives the sun gear to rotate, which in turn drives multiple planetary gears meshing with the sun gear and a gear ring disk meshing with the planetary gears to rotate together. Thus, the speed-increasing effect is achieved through the arrangement of the planetary gears, thereby increasing the generator's speed and power density. Simultaneously, by arranging the sun gear and planetary gears on one side of the drive unit, the sun gear and planetary gears can be integrated with the drive unit, reducing the generator's longitudinal arrangement space. This allows for meeting the assembly requirements of a direct-drive connection while ensuring performance requirements.

[0029] The speed-increasing method of the present invention has the same beneficial effects as the speed-increasing generator structure described above, since it adopts the speed-increasing generator structure described above. Therefore, it will not be described again here.

[0030] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 An axial cross-sectional view of the speed-increasing generator structure in an embodiment of the present invention is shown;

[0033] Figure 2 A circumferential cross-sectional view of the speed-increasing generator structure in an embodiment of the present invention is shown;

[0034] Figure 3 A flowchart of the speed-up method in an embodiment of the present invention is shown.

[0035] In the figure, 100 is the drive unit; 110 is the housing; 111 is the connecting shaft; 112 is the connecting bearing; 120 is the drive shaft; 121 is the first fixed bearing; 122 is the second fixed bearing; 130 is the rotor; 140 is the stator; 150 is the first ring plate; 160 is the first limiting sleeve; 170 is the second ring plate; 180 is the second limiting sleeve; 190 is the elastic pad; 200 is the sun gear; 300 is the planet gear; and 400 is the gear ring disk. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] Reference Figure 1 This invention provides a speed-increasing generator structure, including: a drive unit 100, a sun gear 200, a ring gear disk 400, and planet gears 300. A drive shaft 120 is mounted on the drive unit 100. The sun gear 200 is disposed on one side of the drive unit 100 and coaxially connected to one end of the drive shaft 120. The ring gear disk 400 is disposed on one side of the drive unit 100, with the sun gear 200 positioned between the drive unit 100 and the ring gear disk 400. The outer edge of the ring gear disk 400 near the drive unit 100 has internal teeth arranged circumferentially around the drive shaft 120. Multiple planet gears 300 are rotatably disposed on one side of the drive unit 100 and evenly arranged circumferentially around the drive shaft 120, such that each planet gear 300 meshes with the internal teeth of the ring gear disk 400 and the sun gear 200. The side of the gear ring 400 away from the drive unit 100 is connected to the engine shaft.

[0038] Specifically, one end of the drive shaft 120 of the drive unit 100 extends outside the drive unit 100. The sun gear 200 is disposed on the outside of the drive unit 100 and coaxially connected to the end of the drive shaft 120 extending outside the drive unit 100. Multiple planet gears 300 are also rotatably disposed on the outside of the drive unit 100, located on the same side as the sun gear 200. The multiple planet gears 300 are evenly arranged around the circumference of the drive shaft 120 and mesh with the sun gear 200 respectively. A gear ring disk 400 is disposed on the outside of the drive unit 100. The sun gear 200 and the multiple planet gears 300 are located between the drive unit 100 and the gear ring disk 400. The outer edge of the gear ring disk 400 near the sun gear 200 and planet gears 300 has internal teeth arranged around the circumference of the drive shaft 120. Figure 2The internal teeth of the gear ring disk 400 surround the drive shaft 120 and are arranged around multiple planetary gears 300, so that the multiple planetary gears 300 are respectively meshed with the internal teeth of the gear ring disk 400. The side of the gear ring disk 400 away from the sun gear 200 and planetary gears 300 is connected to the engine shaft.

[0039] When the drive shaft 120 of the drive unit 100 rotates, it drives the sun gear 200 to rotate around the circumference of the drive shaft 120. The rotation of the sun gear 200 drives multiple planet gears 300, each meshing with the sun gear 200, to rotate around their own circumference. The rotation of these planet gears collectively drives a gear ring disk 400, also meshing with the planet gears, to rotate around the circumference of the drive shaft 120, thus driving the engine shaft. The planet gears 300 also increase the generator's speed, thereby increasing its power density. Furthermore, by placing the sun gear 200 and planet gears 300 on one side of the drive unit 100, they can be integrated with the drive unit 100, reducing the generator's longitudinal space and thus meeting the assembly requirements of a direct-drive connection while maintaining performance.

[0040] In some specific embodiments of the present invention, reference is made to... Figure 1 The drive unit 100 includes a housing 110, a rotor 130, and a stator 140. A mounting groove is provided on one side of the housing 110. A drive shaft 120 is rotatably disposed within the housing 110, with one end of the drive shaft 120 passing through the mounting groove. The rotor 130 is located within the housing 110 and is sleeved on the outer periphery of the drive shaft 120. The stator 140 is circumferentially disposed on the inner wall of the housing 110 surrounding the drive shaft 120.

[0041] Specifically, the housing is hollow, and the drive shaft 120 is rotatably mounted inside the housing 110. A mounting groove is provided on one side of the housing 110, and one end of the drive shaft 120 passes through the mounting groove. The sun gear 200 is sleeved on the outer periphery of the end of the drive shaft 120 that passes through the mounting groove, achieving coaxial mounting of the sun gear 200 and the drive shaft 120. The rotor 130 is rotatably mounted inside the housing 110 and fixedly sleeved on the outer periphery of the drive shaft 120. The stator 140 is circumferentially arranged around the drive shaft 120 on the inner wall of the housing 110. Through the interaction between the stator 140 and the rotor 130, the rotor 130 can be driven to rotate, thereby driving the drive shaft 120 to rotate as well, thus achieving drive of the drive shaft 120.

[0042] In some specific embodiments of the present invention, reference is made to... Figure 1The mounting slot is provided with multiple connecting shafts 111, and each of the multiple connecting shafts 111 corresponds to a multiple planetary gears 300. The planetary gears 300 are rotatably mounted on the corresponding connecting shafts 111 through the connecting bearings 112.

[0043] Specifically, three planetary gears 300 are provided. Three connecting shafts 111 are provided at the bottom of the mounting slot, and these three connecting shafts 111 are evenly arranged around the drive shaft 120. Each planetary gear 300 corresponds to one of the three connecting shafts 111. A connecting bearing 112 is fitted onto the outer circumference of each connecting shaft 111, and the planetary gear 300 is fitted onto the connecting bearing 112, allowing the planetary gear 300 to be rotatably connected to its corresponding connecting shaft 111 via the connecting bearing 112. When the drive shaft 120 of the drive unit 100 rotates, causing the sun gear 200 to rotate around its circumference, the rotation of the sun gear 200 drives the three planetary gears 300, each meshing with the sun gear 200, to rotate around their respective connecting shafts 111, thus achieving the driving of the planetary gears 300.

[0044] In some specific embodiments of the present invention, reference is made to... Figure 1 The gear ring disk 400 is placed on the mounting groove, so that the inner teeth of the gear ring disk 400 are embedded in the outer edge of the mounting groove.

[0045] Specifically, an annular plate is circumferentially arranged around the drive shaft 120 at the outer edge of the gear ring disk 400 near the sun gear 200 and planet gears 300. When the gear ring disk 400 is placed on the mounting groove, the annular plate can be embedded within the mounting groove, thus forming an installation space between the side of the gear ring disk 400 near the sun gear 200 and planet gears 300 and the mounting groove. This allows the sun gear 200 and the three planet gears 300 to be located within this installation space. The inner wall of the annular plate is circumferentially arranged around the three planet gears 300 around the drive shaft 120. (Refer to...) Figure 2 The inner wall of the annular plate has multiple internal teeth arranged radially toward the drive shaft 120. These internal teeth are arranged sequentially around the circumference of the drive shaft 120, allowing the three planetary gears 300 to mesh with the gear ring disk 400 through the internal teeth. This not only increases the generator's speed but also reduces the generator's longitudinal layout space, thus meeting the assembly requirements of a direct-drive connection while ensuring performance.

[0046] In some specific embodiments of the present invention, reference is made to... Figure 1 One end of the drive shaft 120 located inside the housing 110 is rotatably connected to the inner wall of the housing 110 via a first fixed bearing 121. The other end of the drive shaft 120 located in the mounting groove is rotatably connected to the side wall of the gear ring disk 400 via a second bearing.

[0047] Specifically, a first embedding groove is formed in the middle of the side of the housing 110 away from the mounting groove, and the first fixed bearing 121 is rotatably embedded in the first embedding groove. A second embedding groove is formed in the middle of the side of the gear ring disk 400 near the housing 110, and the second fixed bearing 122 is rotatably embedded in the second embedding groove, and the first embedding groove and the second embedding groove are coaxially arranged. One end of the drive shaft 120 is inserted into the first fixed bearing 121, and the other end of the drive shaft 120 passes through the mounting groove and is inserted into the second fixed bearing 122, thereby realizing the rotational setting of the drive shaft 120.

[0048] In some specific embodiments of the present invention, reference is made to... Figure 1 The gear ring disk 400 has a stepped structure on the side away from the drive shaft 120, and the stepped structure is embedded and connected to the engine shaft.

[0049] Specifically, a stepped structure is provided on the side of the gear ring disk 400 away from the drive shaft 120. The stepped structure can be threaded into the end face of the engine shaft, thereby facilitating shaft positioning and ensuring assembly accuracy. The stepped structure is located in the middle of the side of the gear ring disk 400 away from the drive shaft 120. A second embedding groove is formed within the stepped structure along the axial direction of the drive shaft 120, thereby reducing the overall thickness of the gear ring disk 400. While ensuring a reduction in the overall thickness of the gear ring disk 400, the size of the second embedding groove is increased. This reduces the longitudinal arrangement space of the generator and ensures the connection stability between the drive shaft 120 and the gear ring disk 400.

[0050] In some specific embodiments of the present invention, reference is made to... Figure 1 An elastic pad 190 is provided between the end face of the drive shaft 120 located in the mounting groove and the side wall of the gear ring disk 400.

[0051] Specifically, the elastic pad 190 is disposed at the bottom of the second embedded groove, so that the elastic pad 190 is located between the end face of the drive shaft 120 and the second fixed bearing 122 and the bottom of the second embedded groove. The elastic pad 190 can absorb the axial clearance error of the generator to ensure operational stability.

[0052] Furthermore, the elastic pad 190 has a wave-like structure, which further enhances its ability to absorb axial clearance errors of the generator, thereby ensuring operational stability.

[0053] It should be noted that the axial clearance error of the generator is mainly caused by the machining error of each component. The setting of the elastic pad 190 can avoid the influence of machining error, alleviate the requirements of machining standards, and avoid excessive cost.

[0054] In some specific embodiments of the present invention, reference is made to... Figure 1A first ring plate 150 is circumferentially arranged around the drive shaft 120 on one side of the rotor 130, and the first ring plate 150 is connected to the drive shaft 120 through a first limiting sleeve 160. A second ring plate 170 is circumferentially embedded around the drive shaft 120 on one side of the sun gear 200, and the second ring plate 170 is connected to the drive shaft 120 through a second limiting sleeve 180.

[0055] Specifically, a first ring plate 150 is circumferentially sleeved around the drive shaft 120 and fitted onto its outer periphery. The first ring plate 150 is located on one side of the rotor 130 and abuts against its side wall, thus supporting the rotor 130 and ensuring its stability. A first limiting sleeve 160 is circumferentially adjacent to the first ring plate 150 and fixedly fitted onto the outer periphery of the drive shaft 120, achieving an interference fit between the first limiting sleeve 160 and the drive shaft 120, and securing the first ring plate 150. A second ring plate 170 is circumferentially embedded in the side wall of the sun gear 200, supporting the sun gear 200 and ensuring its stability. The second limiting sleeve 180 is circumferentially adjacent to the second ring plate 170 and fixedly sleeved on the outer periphery of the drive shaft 120, thereby achieving an interference fit between the second limiting sleeve 180 and the drive shaft 120, and fixing the second ring plate 170 through the second limiting sleeve 180.

[0056] Furthermore, the first ring plate 150 and the second ring plate 170 are provided with multiple de-weighting holes, which are evenly arranged to maintain the dynamic balance requirements of the rotor 130 and the sun gear 200.

[0057] In some specific embodiments of the present invention, reference is made to... Figure 1 The rotor 130 and the drive shaft 120 are integrated into a single structure.

[0058] Specifically, the rotor 130 and the drive shaft 120 are connected by an interference fit, which makes the rotor 130 and the drive shaft 120 form an integrated structure. The rotor 130 and the drive shaft 120 can be considered as a whole for operation, which not only increases the stability of operation, but also reduces the number of parts that need to be assembled and reduces assembly time, thereby achieving the purpose of cost reduction.

[0059] Reference Figure 3This invention also provides a speed-increasing method, employing a speed-increasing generator structure as described in any of the above specific embodiments, comprising the following steps: the drive shaft 120 of the drive unit 100 operates to drive the sun gear 200 to rotate circumferentially around the drive shaft 120. The rotation of the sun gear 200 simultaneously drives multiple planet gears 300 to rotate circumferentially, thereby driving the ring gear disk 400 to rotate circumferentially around the drive shaft 120. The rotation of the ring gear disk 400 drives the engine shaft to rotate, achieving speed increase.

[0060] Specifically, when the rotor 130 and stator 140 of the drive unit 100 of the speed-increasing generator structure rotate in coordination with the drive shaft 120, they drive the sun gear 200 to rotate around the circumference of the drive shaft 120. The rotation of the sun gear 200 drives the three planetary gears 300 meshed with it to rotate around their respective connecting shafts 111. The rotation of these planetary gears collectively drives the gear ring disk 400 meshed with the three planetary gears to rotate around the circumference of the drive shaft 120, thus driving the engine shaft. The arrangement of the planetary gears 300 achieves the speed-increasing purpose of the generator, thereby increasing the generator's speed and power density. Simultaneously, by placing the sun gear 200 and planetary gears 300 on one side of the drive unit 100, the sun gear 200 and planetary gears 300 can be integrated with the drive unit 100, reducing the longitudinal space required for the generator. This allows for meeting the assembly requirements of a direct-drive connection while ensuring performance.

[0061] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A speed-increasing generator structure, characterized in that, include: A drive unit (100) is provided with a drive shaft (120); A sun gear (200) is disposed on one side of the drive unit (100), and the sun gear (200) is coaxially connected to one end of the drive shaft (120); A gear ring disk (400) is disposed on one side of the drive unit (100), such that the sun gear (200) is located between the drive unit (100) and the gear ring disk (400), and the outer edge of the gear ring disk (400) near the drive unit (100) is provided with internal teeth around the drive shaft (120) in the circumferential direction; Planetary gears (300), multiple planetary gears (300) are provided, and multiple planetary gears (300) are rotatably disposed on one side of the drive unit (100), and multiple planetary gears (300) are evenly arranged around the drive shaft (120) in the circumference, so that each planetary gear (300) is meshed and connected with the internal teeth of the gear ring disk (400) and the sun gear (200); The gear ring disk (400) is connected to the engine shaft on the side away from the drive unit (100); The drive unit (100) includes: A housing (110) having a mounting groove on one side; The drive shaft (120) is rotatably disposed within the housing (110), and one end of the drive shaft (120) passes through the mounting groove; Rotor (130), the rotor (130) is located inside the housing (110), and the rotor (130) is sleeved on the outer periphery of the drive shaft (120); A stator (140) is circumferentially disposed on the inner wall of the housing (110) surrounding the drive shaft (120); The gear ring disk (400) has a stepped structure on the side away from the drive shaft (120), and the stepped structure is embedded and connected to the engine shaft; An elastic pad (190) is provided between the end face of the drive shaft (120) located in the mounting groove and the side wall of the gear ring disk (400); A first ring plate (150) is provided on one side of the rotor (130) around the drive shaft (120) in the circumferential direction. The first ring plate (150) is connected to the drive shaft (120) through a first limiting sleeve (160). A second ring plate (170) is circumferentially embedded on one side of the sun gear (200) around the drive shaft (120), and the second ring plate (170) is connected to the drive shaft (120) through a second limiting sleeve (180).

2. The speed-increasing generator structure according to claim 1, characterized in that, The mounting slot is provided with a plurality of connecting shafts (111), and the plurality of connecting shafts (111) correspond one-to-one with the plurality of planetary gears (300). The planetary gears (300) are rotatably mounted on the corresponding connecting shafts (111) through connecting bearings (112).

3. The speed-increasing generator structure according to claim 1, characterized in that, The gear ring disc (400) is placed on the mounting groove, so that the inner teeth of the gear ring disc (400) are embedded in the outer edge of the mounting groove.

4. The speed-increasing generator structure according to claim 3, characterized in that, One end of the drive shaft (120) located inside the housing (110) is rotatably connected to the inner wall of the housing (110) via a first fixed bearing (121); One end of the drive shaft (120) located in the mounting groove is rotatably connected to the side wall of the gear ring disk (400) via a second bearing.

5. The speed-increasing generator structure according to claim 1, characterized in that, The rotor (130) and the drive shaft (120) are an integrated structure.

6. A speed-increasing method, employing the speed-increasing generator structure as described in any one of claims 1 to 5, characterized in that, Includes the following steps: The drive shaft (120) of the drive unit (100) operates to drive the sun gear (200) to rotate circumferentially around the drive shaft (120); The rotation of the sun gear (200) simultaneously drives multiple planet gears (300) to rotate circumferentially, thereby driving the gear ring disk (400) to rotate circumferentially around the drive shaft (120); The speed is increased by rotating the engine shaft through the rotation of the gear ring disc (400).

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