Generator, range extending power assembly and electric vehicle

Abstract

The invention provides an electric generator, a range extending power assembly and an electric vehicle, and relates to the technical field of electric vehicles, the electric generator is used for being in transmission connection with an engine of the range extending electric vehicle, a shell of the electric generator is used for containing a stator and a rotor of the electric generator, and a cooling liquid flow channel of the electric generator is used for conveying cooling liquid to cool the stator or the rotor. The rotor comprises a plurality of fixing holes which are arranged at intervals in the circumferential direction of the generator, each fixing hole penetrates through the rotor in the axial direction of the generator and is used for containing a fixing piece, and the fixing pieces are used for fixedly connecting the rotor and a crankshaft of the engine, so that the rotor is directly and fixedly connected with the crankshaft, and flywheel discs of the engine can be reduced. The rotor is used for fixing the cover plate, the cover plate is distributed on the side, away from the crankshaft, of the rotor in the axial direction of the generator, and the cover plate is used for sealing one or more fixing holes, so that cooling liquid in a shell of the generator can be prevented from leaking from gaps between the fixing holes and the fixing pieces, and the reliability and safety of the generator are improved.

Description

Technical Field

[0001] This application relates to the field of electric vehicle technology, and in particular to a generator, a range extender powertrain, and an electric vehicle. Background Technology

[0002] In range-extended electric vehicles, the range-extending powertrain can charge the power battery. In the range-extending powertrain, the rotor of the generator is directly fixed to the crankshaft of the engine. The coolant in the generator cavity is prone to leakage, which affects the reliability and safety of the generator. The sealing structure of the generator cavity needs to be improved. Summary of the Invention

[0003] This application provides a generator, a range extender powertrain, and an electric vehicle, which uses a cover plate to seal the mounting holes of the rotor for fixed connection with the crankshaft, thereby preventing coolant leakage from the mounting holes inside the generator housing.

[0004] In a first aspect, this application provides a generator for driving and connecting an engine of a range-extended electric vehicle. The generator housing houses the generator stator and rotor, and coolant channels deliver coolant to cool the stator or rotor. The rotor includes multiple fixing holes spaced circumferentially along the generator's axis, each hole penetrating the rotor along the generator's axial direction. Each fixing hole accommodates a fixing member for securely connecting the rotor to the engine's crankshaft. A cover plate is also provided on the rotor, located on the side of the rotor facing away from the crankshaft along the generator's axial direction, and seals one or more fixing holes.

[0005] In this embodiment, the rotor and crankshaft are directly fixedly connected through multiple fixing holes of the rotor. The rotor of the generator realizes the function of the engine's flywheel, eliminating the flywheel and reducing the overall axial dimension of the engine and generator. This optimizes the layout of the engine and generator in the vehicle. A cover plate is fixed on the side of the rotor away from the crankshaft along the generator's axial direction. The cover plate seals the fixing holes, thereby preventing coolant leakage from the generator housing through the gap between the fixing holes and the fixing parts, thus improving the reliability and safety of the generator.

[0006] In one embodiment, the rotor, on the side of the generator facing away from the crankshaft along the generator's axial direction, is also used to fix the seal. The axial seals are distributed between the rotor and the cover plate, while the circumferential seals are distributed around the fixing holes. The cover plate is used to compress the seals to achieve a reliable seal in the fixing holes, improving the sealing effect of the cover plate on the fixing holes.

[0007] In one embodiment, the cover plate includes a plurality of first fixing holes, which are arranged at intervals along the circumference of the generator. These first fixing holes are used to fix the cover plate and the rotor through a fixing member, and are distributed around the sealing member along the circumference of the generator. The first fixing holes are used to fix the cover plate to the rotor, and the fixing member in the first fixing holes can apply a compressive force to the cover plate, improving the reliability of the sealing member's sealing of the fixing holes and enhancing the sealing effect of the cover plate's sealing of the fixing holes.

[0008] In one embodiment, the housing is also used to house a mechanical pump for delivering coolant to the generator's coolant channels, and a cover plate is used for drive connection between the rotor and the mechanical pump.

[0009] In this embodiment, the cover plate is used to drive the rotor and the mechanical pump. The cover plate, which is used to seal the rotor's mounting holes, drives the mechanical pump, resulting in a higher degree of structural integration in the range-extender powertrain. This contributes to a more compact structure and reduces the axial dimension occupied by the generator housing. Reusing the cover plate to drive the rotor and mechanical pump also helps to increase the power density of the range-extender powertrain.

[0010] In one embodiment, the rotor further includes an axial groove distributed on the side of the rotor facing away from the crankshaft along the generator's axial direction. The opening of the axial groove faces away from the crankshaft along the generator's axial direction, and the bottom of the axial groove is used to fix the cover plate. The housing also serves to fix a mechanical pump, which is located on the side of the housing facing the axial groove. The outer diameter of the mechanical pump is smaller than the inner diameter of the axial groove, and the space between the cover plate and the housing along the generator's axial direction is used to accommodate a portion of the mechanical pump.

[0011] In this embodiment, axial grooves are distributed on the side of the rotor away from the crankshaft along the axial direction of the generator. The groove openings of the axial grooves are away from the crankshaft along the axial direction of the generator. The bottom of the axial grooves is used to fix the cover plate, so that the cover plate can be arranged using the axial grooves of the rotor, so that the cover plate does not occupy additional axial space outside the rotor. This is beneficial to make the rotor and cover plate as a whole smaller in axial dimension along the generator, and also beneficial to make the axial dimension of the generator smaller.

[0012] In this embodiment, the housing also serves to fix a mechanical pump, which is located on the side of the housing facing the axial groove. The outer diameter of the mechanical pump is smaller than the inner diameter of the axial groove. The space between the cover plate and the housing along the generator's axial direction is used to accommodate a portion of the mechanical pump. The cover plate is fixed to the bottom of the axial groove, thereby allowing for a larger distance between the cover plate and the housing along the generator's axial direction. This facilitates the mechanical pump's arrangement using the space between the cover plate and the housing along the generator's axial direction without interference with the cover plate. The larger distance between the cover plate and the housing along the generator's axial direction also allows for a larger axial dimension of the mechanical pump. Enlarging the mechanical pump increases the flow velocity of the coolant delivered by the mechanical pump to the generator's coolant channels, improving the cooling effect of the generator's coolant channels on the generator's rotor and stator, and enhancing the generator's stability and reliability.

[0013] In one embodiment, the outer diameter of the cover plate is smaller than the inner diameter of the axial groove. The cover plate and the groove wall of the axial groove are arranged at intervals along the radial direction of the generator to facilitate fixing the cover plate to the rotor. Then, glue is filled between the cover plate and the rotor. The gap between the cover plate and the groove wall of the axial groove needs to be sufficient to allow a dispensing device to reach in and fill the sealant between the cover plate and the bottom of the axial groove.

[0014] In one embodiment, the cover plate includes a first axial protrusion distributed on the side of the cover plate opposite to the rotor along the axial direction of the generator, and the first axial protrusion is used for drive connection of a mechanical pump.

[0015] In this embodiment, the first axial protrusion is distributed on the side of the cover plate away from the rotor along the axial direction of the generator. The first axial protrusion is used to drive the mechanical pump, so that the power of the rotor drive can be output to the mechanical pump through the first axial protrusion of the cover plate. This makes the transmission structure of the cover plate driving the rotor and the mechanical pump simpler and reduces the assembly difficulty.

[0016] In one embodiment, the generator includes a drive shaft for driving a connection between a cover plate and a mechanical pump. The drive shaft is distributed axially between the cover plate and the mechanical pump, with one end of the drive shaft for embedding into the cover plate and the other end for driving the mechanical pump to rotate.

[0017] In this embodiment, the drive shaft is distributed along the axial direction of the generator between the cover plate and the mechanical pump. One end of the drive shaft is used to embed into the cover plate, and the other end is used to drive the mechanical pump to rotate, so that the cover plate can transmit power to the mechanical pump through the drive shaft. Using the drive shaft as an intermediate transmission structure between the cover plate and the mechanical pump also helps to improve the reliability of the rotor-driven mechanical pump.

[0018] In this embodiment, a drive shaft is used as an intermediate transmission structure between the cover plate and the mechanical pump, which allows the axial length of the drive shaft to be flexibly adjusted according to the axial distance between the cover plate and the mechanical pump to achieve transmission between the cover plate and the mechanical pump.

[0019] In one embodiment, the first axial protrusion of the cover plate includes a groove, the opening of which faces the drive shaft along the axial direction of the generator, and one end of the drive shaft is used to be embedded in the groove of the first axial protrusion.

[0020] In this embodiment, one end of the drive shaft is embedded in the groove of the first axial protrusion, which facilitates the positioning of the drive shaft, making the assembly process between the drive shaft and the cover plate simpler and easier for the drive shaft to receive power from the cover plate. The distance between the first axial protrusion and the mechanical pump along the generator axis is small. The drive shaft is embedded in the groove of the first axial protrusion, which allows the axial length of the drive shaft to be shortened, improving the reliability of the drive shaft's transmission connection between the cover plate and the mechanical pump.

[0021] In one embodiment, the axial length of the cover plate along the generator axis is less than the groove depth of the axial groove. The drive shaft is used to drive the connection between the cover plate and the mechanical pump. The axial groove of the rotor is used to accommodate a part of the drive shaft, so that the drive shaft can be arranged using part of the axial space of the rotor, which is beneficial to make the rotor and the mechanical pump more compactly arranged along the generator axis.

[0022] In one embodiment, the axial groove of the rotor is used to accommodate a portion of the drive shaft and a portion of the mechanical pump, so that the mechanical pump can be arranged using part of the axial space of the rotor. This facilitates increasing the axial dimension of the mechanical pump, which is beneficial to increasing the flow rate of the coolant delivered by the mechanical pump to the coolant channel of the generator, improving the cooling effect of the coolant channel on the generator rotor and stator, and improving the stability and reliability of the generator.

[0023] In one embodiment, each mounting hole of the rotor includes a first segment and a second segment. Along the axial direction of the generator, the first segment is closer to the cover plate than the second segment. The inner diameter of the first segment is larger than the inner diameter of the second segment. The first segment is used to accommodate the fastening end of the fastener. The second segment is used to pass through the mounting hole of the fastener extending into the crankshaft. Along the axial direction of the generator, the axial length of the first segment is greater than the axial length of the fastening end of the fastener accommodated in the first segment.

[0024] In this embodiment, the axial length of the first segment along the generator's axial direction is greater than the axial length of the fastening end of the fastener accommodated in the first segment. This larger axial length of the first segment allows the fastening end of the fastener to be fully accommodated within the fixing hole, ensuring that the fastening end of the fastener does not obstruct the mounting of the cover plate to the rotor sealing fixing hole. It also results in a smaller axial gap between the cover plate and the fixing hole, facilitating the sealing of the fixing hole. Furthermore, it makes it easier to make the portion of the cover plate covering the fixing hole flat, simplifying the cover plate manufacturing process. The larger axial length of the first segment along the generator's axial direction also allows for weight reduction of the rotor.

[0025] In one embodiment, when the fixing hole is sealed by filling the gap between the rotor and the cover plate along the axial direction of the generator with sealant, the axial length of the first segment along the axial direction of the generator is greater than the axial length of the fastening end of the fastener accommodated in the first segment, which makes the gap between the rotor and the cover plate smaller and easier to seal with sealant.

[0026] In one embodiment, the inner diameter of the first segment of each fixing hole is larger than the outer diameter of the fastening end of the fixing member. Making the inner diameter of the first segment larger can reduce the weight of the rotor.

[0027] In one embodiment, the rotor further includes a first receiving groove distributed on the side of the rotor facing the crankshaft, the opening of the first receiving groove facing the crankshaft along the axial direction of the generator, and a plurality of fixing holes distributed around the first receiving groove, the first receiving groove being used to accommodate the insertion of the crankshaft.

[0028] In this embodiment of the application, the opening of the first receiving groove of the rotor faces the crankshaft along the axial direction of the generator, and a plurality of fixing holes are distributed around the first receiving groove. The first receiving groove is used to accommodate the insertion of the crankshaft, so that before the fixing member passes through the fixing hole to fix the rotor and the crankshaft, the rotor can be positioned with the crankshaft through the first receiving groove of the rotor, which facilitates the fixed connection between the rotor and the crankshaft.

[0029] In this embodiment, the rotor includes a first receiving groove, and the rotor can also be made lighter.

[0030] In one embodiment, the rotor further includes a second receiving groove distributed on the side of the rotor away from the crankshaft. The opening of the second receiving groove is away from the crankshaft along the axial direction of the generator. A plurality of fixing holes are distributed around the second receiving groove, which is used to accommodate the embedding of the cover plate.

[0031] In this embodiment, the opening of the second receiving groove is away from the crankshaft along the axial direction of the generator, and multiple fixing holes are distributed around the second receiving groove. The second receiving groove is used to accommodate the embedding of the cover plate, so that after the rotor is fixed to the crankshaft, the cover plate can be positioned with the rotor through the second receiving groove of the rotor, simplifying the assembly process of fixing the cover plate to the rotor.

[0032] In this embodiment, multiple fixing holes are distributed around the second receiving groove, which is beneficial to seal the opening of the second receiving groove when the cover plate seals the fixing holes, thus preventing the coolant in the generator housing from leaking from the second receiving groove.

[0033] In this embodiment, the rotor includes a second receiving groove, and the rotor can also be made lighter.

[0034] In one embodiment, the cover plate includes a third axial protrusion distributed on one side of the cover plate facing the rotor along the axial direction of the generator. The third axial protrusion is used to be embedded in a second receiving groove to facilitate the positioning and assembly between the cover plate and the rotor.

[0035] In one embodiment, the rotor further includes a weight-reducing through hole that extends along the axial direction of the generator through the bottom of the first receiving groove and the bottom of the second receiving groove, and the cover plate is also used to seal the opening of the second receiving groove.

[0036] In this embodiment, the weight-reducing through-hole connects the first receiving groove and the second receiving groove, facilitating the simultaneous processing of the first and second receiving grooves and simplifying the rotor's manufacturing process. This allows not only the rotor and crankshaft to be positioned via the first receiving groove, and the cover plate and rotor to be positioned via the second receiving groove, reducing assembly difficulty, but also enables the rotor to be weight-reduced through the first receiving groove, the second receiving groove, and the weight-reducing through-hole.

[0037] In this embodiment of the application, the cover plate is also used to seal the opening of the second receiving tank, so that the coolant in the generator housing will not leak from the second receiving tank, the weight reduction through hole and the second receiving tank.

[0038] In one embodiment, the rotor includes a first through-hole extending through the rotor along the axial direction of the generator. One opening of the first through-hole along the axial direction of the generator faces the crankshaft for receiving the insertion of the crankshaft, and another opening of the first through-hole along the axial direction of the generator faces away from the crankshaft for receiving the insertion of a cover plate for sealing the other opening of the first through-hole.

[0039] In this embodiment, the rotor includes a first through hole, which facilitates the positioning of the rotor and crankshaft, as well as the positioning of the cover plate and rotor, simplifying the assembly process. The machining process of the first through hole is simple. The first through hole can also reduce the weight of the rotor.

[0040] In this embodiment of the application, the cover plate is used to seal another opening of the first through hole, thereby preventing coolant in the generator housing from leaking from the first through hole.

[0041] In one embodiment, the first through hole of the rotor includes a third segment and a fourth segment. Along the axial direction of the generator, the third segment is closer to the crankshaft than the fourth segment. The inner diameter of the third segment is larger than the inner diameter of the fourth segment. The third segment is used to accommodate the insertion of the crankshaft, and the fourth segment is used to accommodate the insertion of the cover plate.

[0042] In this embodiment, the third segment has a larger inner diameter, which facilitates the insertion of a crankshaft with a larger outer diameter into the third segment. The fourth segment has a smaller inner diameter, which allows the cover plate to be inserted into the fourth segment and seal a smaller outer diameter, thus reducing the risk of coolant leakage from the fourth segment through the first through hole.

[0043] In one embodiment, the generator housing includes a first housing and a second housing. The first housing is used to fix and connect the engine housing. The first housing has a slot-shaped structure. The slot of the first housing faces away from the engine along the axial direction of the generator. The slot of the first housing is used to accommodate the insertion of the stator. The central hole of the stator is used to accommodate the insertion of the rotor. The second housing is used to enclose the slot of the first housing.

[0044] In this embodiment, the first housing is used to fix the housing of the engine. The first housing is a slot-shaped structure. The slot of the first housing faces away from the engine along the axial direction of the generator. The slot of the first housing is used to accommodate the insertion of the stator. The central hole of the stator is used to accommodate the insertion of the rotor. The rotor is used to fix the cover plate. The cover plate is distributed on the side of the rotor facing away from the crankshaft along the axial direction of the generator. This allows the stator, rotor and cover plate to be assembled from the slot direction of the first housing, realizing unidirectional assembly, which helps to simplify the assembly process.

[0045] In this embodiment of the application, the second housing is used to enclose the slot of the first housing, which can prevent the coolant inside the generator housing from leaking from the slot of the first housing.

[0046] In one embodiment, the mating surfaces of the first housing and the second housing are sealed with sealant.

[0047] In one embodiment, the slot of the first housing faces away from the engine along the generator's axial direction, while the slot of the first receiving groove faces the crankshaft along the generator's axial direction. The orientation of the slot of the first housing is opposite to that of the slot of the first receiving groove. This allows the rotor to be assembled into the first housing from the slot on the side of the first housing facing away from the engine after the first housing is fixed to the engine housing. At the same time, the first receiving groove faces the crankshaft. When the first receiving groove accommodates the embedded crankshaft, it can be used to position the rotor relative to the crankshaft, which simplifies the rotor assembly process.

[0048] In one embodiment, the slot of the first housing faces away from the engine along the generator's axial direction, and the slot of the second receiving slot faces away from the crankshaft along the generator's axial direction. The slots of the first housing and the second receiving slot face the same direction. This allows the rotor to be installed from the slot direction of the first housing, and the cover plate to be inserted into the second receiving slot of the rotor from the slot direction of the first housing. This also allows the generator stator, generator rotor, and cover plate to be assembled sequentially from the slot direction of the first housing, simplifying the assembly process.

[0049] In one embodiment, the second housing is used to fix a mechanical pump, which is located on the side of the second housing facing the axial groove of the rotor. The space between the cover plate along the generator's axial direction and the second housing is used to accommodate a portion of the mechanical pump. This allows the second housing to enclose the groove of the first housing while simultaneously enabling the mechanical pump to be assembled with the first axial protrusion of the cover plate or with the generator's drive shaft, simplifying the assembly process.

[0050] In one embodiment, the bottom of the first housing includes an axial through hole, the rotor includes a second axial protrusion, a fixing hole extends through the second axial protrusion along the axial direction of the generator, the second axial protrusion is distributed on the side of the rotor facing the crankshaft, and the gap between the hole wall of the axial through hole and the second axial protrusion along the radial direction of the generator is used to accommodate a seal.

[0051] In this embodiment, since the first housing is fixedly connected to the engine housing, the rotor needs to be assembled from the slot of the first housing away from the engine. The bottom of the slot of the first housing includes an axial through hole, and the rotor includes a second axial protrusion. The fixing hole passes through the second axial protrusion along the axial direction of the generator, so that the second axial protrusion of the rotor can pass through the axial through hole to achieve a fixed connection with the crankshaft.

[0052] In this embodiment, the radial gap between the wall of the axial through hole and the second axial protrusion of the generator is used to accommodate the seal, so that the second axial protrusion of the rotor and the wall of the axial through hole can be radially sealed by the seal, thereby preventing the coolant in the generator housing from leaking from the gap between the axial through hole of the first housing and the second axial protrusion.

[0053] In this embodiment, the second axial protrusion penetrates the axial through hole of the first housing, and the fixing hole passes through the second axial protrusion along the axial direction of the generator. The fixing hole is sealed with a cover plate, so that the cover plate can achieve axial sealing with the rotor, thereby preventing the coolant in the generator housing from leaking from the fixing hole to the outside of the axial through hole of the first housing.

[0054] In this embodiment, a seal is used to seal the generator housing and the rotor, and a cover plate is used to seal the fixing hole. These two seals isolate the inner cavity of the generator housing from the outside, thereby improving the sealing reliability of the generator housing.

[0055] In one embodiment, the seal is fixedly sealed to the wall of the axial through hole, and dynamically sealed to the second axial protrusion of the rotor, so that the second axial protrusion of the rotor can be sealed to the first housing without affecting the rotation of the rotor.

[0056] In one embodiment, the second axial protrusion includes a first receiving groove distributed on the side of the second axial protrusion facing the crankshaft, so that the crankshaft can be embedded in the first receiving groove of the second axial protrusion, and the weight of the second axial protrusion of the rotor can also be reduced.

[0057] In one embodiment, the wall of the axial through hole protrudes from the inner side of the first housing along the axial direction of the generator, and the rotor includes an annular groove distributed on the side of the rotor facing the engine. The annular groove is used to avoid the wall of the axial through hole.

[0058] In this embodiment, the wall of the axial through hole protrudes from the inner side of the first housing along the axial direction of the generator, which can make the wall of the axial through hole have a larger axial dimension, making it convenient for the hole wall of the axial through hole to fix the sealing element and the second axial protrusion of the rotor to achieve sealing.

[0059] In this embodiment, the rotor includes an annular groove, which can reduce the weight of the rotor.

[0060] In this embodiment, the annular groove is distributed on the side of the rotor facing the engine. The annular groove is used to avoid the hole wall of the axial through hole, so that the hole wall of the axial through hole can be arranged more compactly with the rotor along the axial direction of the generator. It can also make the seal between the hole wall of the axial through hole and the second axial protrusion arranged using part of the axial space of the annular groove, which is beneficial to make the generator structure compact and occupy a small axial dimension.

[0061] In one embodiment, the wall of the axial through hole protrudes from the side of the first housing facing the engine along the axial direction of the generator, and the depth of the groove bottom of the first housing recessed towards the center hole of the stator along the axial direction of the generator is equal to or greater than the dimension of the wall of the axial through hole protruding from the outside of the first housing.

[0062] In this embodiment, the wall of the axial through hole protrudes from the side of the first housing facing the engine along the axial direction of the generator, so that the wall of the axial through hole has a larger axial dimension, which makes it easier for the hole wall of the axial through hole to fix the seal and the second axial protrusion of the rotor to achieve sealing.

[0063] In this embodiment, the depth of the groove bottom of the first housing recessed along the generator's axial direction toward the central hole of the stator is equal to or greater than the dimension of the axial through hole wall protruding outward from the first housing. A greater depth of recess in the groove bottom of the first housing along the generator's axial direction toward the central hole of the stator avoids increasing the axial dimension of the first housing due to the axial through hole wall protruding outward from the engine side, thus contributing to a smaller axial dimension of the generator housing. The greater depth of recess in the groove bottom of the first housing along the generator's axial direction toward the central hole of the stator also avoids obstructing the sealing structure between the engine housing and the crankshaft, resulting in a smaller overall axial dimension of the generator and engine structure. Furthermore, it achieves radial sealing between the rotor and the generator's first housing without interfering with the sealing between the engine housing and the crankshaft.

[0064] In one embodiment, the rotor includes a rotor support and a rotor core, the rotor support being used to directly fix the crankshaft and to fix the rotor core, and a fixing hole penetrating the rotor support along the axial direction of the generator.

[0065] In this embodiment, the rotor bracket is used to directly fix the crankshaft and to fix the rotor core, so that the rotor can be fixedly connected to the crankshaft through the rotor bracket.

[0066] In this embodiment, the fixing hole penetrates the rotor support along the axial direction of the generator, and the cover plate is distributed on the side of the rotor support away from the crankshaft along the axial direction of the generator. The cover plate seals the fixing hole on the rotor support, so that the coolant inside the generator housing will not leak from the fixing hole of the rotor support to the outside of the housing.

[0067] In one embodiment, axial grooves for fixing the cover plate are distributed on the side of the rotor support opposite to the crankshaft along the axial direction of the generator, and the axial grooves are formed directly by the rotor support.

[0068] In one embodiment, the axial groove is formed by the rotor support and the rotor core together.

[0069] Secondly, this application provides a range extender powertrain, which includes a generator controller and a generator as described in the first aspect. The generator controller is used to receive alternating current generated by the generator and to output direct current to charge the power battery of the electric vehicle.

[0070] In the embodiments of this application, the generator utilizes multiple fixing holes on the rotor to achieve a direct fixed connection between the rotor and the crankshaft. The generator rotor functions as the engine's flywheel, eliminating the flywheel and reducing the overall axial dimension of the engine and generator. This results in a smaller axial dimension of the range extender powertrain, optimizing its layout within the vehicle. A cover plate is fixed to the side of the rotor away from the crankshaft along the generator's axial direction. The cover plate seals the fixing holes, preventing coolant leakage from the generator housing through the gap between the fixing holes and the fixing components. This improves the generator's reliability and safety, and enhances the performance of the range extender powertrain.

[0071] Thirdly, this application provides an electric vehicle including a power battery and a range-extending powertrain as described in the second aspect, the range-extending powertrain being used to charge the power battery.

[0072] The range extender powertrain in this embodiment includes a generator. The generator uses multiple fixing holes on the rotor to achieve a direct fixed connection between the rotor and the crankshaft. The rotor of the generator performs the function of the engine's flywheel, eliminating the flywheel and reducing the overall axial dimension of the engine and generator. This results in a smaller axial dimension of the range extender powertrain, optimizing its layout within the vehicle. A cover plate is fixed on the side of the rotor away from the crankshaft along the generator's axial direction. The cover plate seals the fixing holes, preventing coolant leakage from the generator housing through the gap between the fixing holes and the fixing components. This improves the reliability and safety of the generator, enhances the performance of the range extender powertrain, and ultimately improves the overall performance of the vehicle. Attached Figure Description

[0073] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments of this application will be described below.

[0074] Figure 1 This is a schematic diagram of an electric vehicle provided in this application. Figure 2 This is a schematic diagram of a range-extended powertrain provided in an embodiment of this application; Figure 3 This is another schematic diagram of the powertrain assembly provided in the embodiments of this application; Figure 4 This is an exploded view of a range-extended powertrain provided in an embodiment of this application; Figure 5 This is an exploded view of the rotor and cover plate provided in an embodiment of this application; Figure 6 This is a cross-sectional view of the rotor and cover plate provided in an embodiment of this application; Figure 7 This is another schematic diagram of the range-extended powertrain provided in the embodiments of this application; Figure 8 This is a partial exploded view of the range-extended powertrain provided in an embodiment of this application; Figure 9 yes Figure 6 A partial enlarged view of the M1 section of the rotor and cover plate; Figure 10 This is a schematic diagram of a rotor provided in an embodiment of this application; Figure 11 This is another schematic diagram of the rotor provided in the embodiments of this application; Figure 12 This is a schematic diagram of a first housing provided in an embodiment of this application; Figure 13 yes Figure 3 A partial enlarged view of the M2 section of the range-extending powertrain. Detailed Implementation

[0075] The technical solutions of the embodiments of this application will be described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0076] This application provides a generator for driving the engine of a range-extended electric vehicle. The generator housing houses the generator stator and rotor, and the generator coolant channels deliver coolant to cool the stator or rotor. The rotor includes multiple fixing holes spaced circumferentially along the generator's axis, each hole penetrating the rotor along the generator's axial direction. Each fixing hole accommodates a fixing member for securely connecting the rotor to the engine's crankshaft. A cover plate is provided on the rotor's axial side away from the crankshaft, sealing one or more fixing holes.

[0077] The rotor is directly fixed to the crankshaft through multiple fixing holes. The rotor of the generator functions as a flywheel, eliminating the flywheel of the engine and reducing the overall axial dimension of the engine and generator. A cover plate is fixed on the side of the rotor away from the crankshaft along the axis of the generator. The cover plate seals the fixing holes, thereby preventing the coolant in the generator housing from leaking from the gap between the fixing holes and the fixing parts, thus improving the reliability and safety of the generator.

[0078] This application provides a generator that can be applied to a range-extending powertrain, which can be used in electric vehicles to improve the overall performance of electric vehicles.

[0079] Figure 1 This is a schematic diagram of an electric vehicle 1 provided in this application.

[0080] In one embodiment, the electric vehicle 1 includes a range-extending powertrain 10, a frame 20, and a power battery 30, such as Figure 1 As shown, the frame 20 is used to fix the range extender powertrain 10 and the power battery 30. The range extender powertrain 10 can charge the power battery 30.

[0081] Figure 2 This is a schematic diagram of a range extender powertrain 10 provided in an embodiment of this application. Figure 3 This is another schematic diagram of the powertrain 10 provided in the embodiments of this application.

[0082] In one embodiment, the range extender powertrain 10 includes a generator controller 11 and a generator 12. For example... Figure 2 As shown, the generator controller 11 can receive the AC power generated by the generator 12. The power module of the generator controller 11 converts the AC power into DC power, which is then used to charge the power battery 30 through the DC bus.

[0083] In one embodiment, the generator controller 11 and the generator 12 are arranged along the axial direction O of the generator 12. This allows the generator controller 11 to be arranged using the radial space occupied by the generator 12, so that the generator controller 11 does not occupy too much space in the height direction of the range extender powertrain 10.

[0084] In one embodiment, such as Figure 2 and Figure 3 As shown, the range extender powertrain 10 also includes an engine 13, which is used to output power. For example, the engine 13 can be a combustion engine, including gasoline engines and diesel engines. In this embodiment, the generator 12 is connected to the engine 13 in a transmission connection. The engine 13 provides power to the generator 12, and the generator 12 converts the kinetic energy output by the engine 13 into electrical energy.

[0085] In one embodiment, the engine 13, generator 12 and generator controller 11 are arranged sequentially along the axial direction O of the generator 12, so that the range extender powertrain 10 can have a smaller dimension in the height direction, thus optimizing the layout of the range extender powertrain 10 in the vehicle.

[0086] To improve the adaptability and power generation efficiency of range extender powertrains, the trend is towards removing the engine flywheel and directly fixing the generator rotor to the engine crankshaft. Using coolant to cool the generator can improve the power density of the range extender powertrain compared to using cooling water. However, when using coolant, the coolant in the generator cavity is prone to leakage, which affects the reliability and safety of the generator. Therefore, it is necessary to improve the sealing structure of the generator cavity.

[0087] This application fixes a cover plate on the side of the rotor away from the crankshaft along the generator's axial direction. The cover plate seals the fixing holes in the rotor that are used to fix it to the crankshaft, thereby preventing coolant in the generator's housing cavity from leaking out of the fixing holes and improving the generator's reliability and safety.

[0088] The generator 12 provided in the embodiments of this application will be described in detail below.

[0089] Figure 4 This is an exploded view of the range extender powertrain 10 provided in an embodiment of this application. Figure 5 This is an exploded view of the rotor 300 and cover plate 400 provided in an embodiment of this application. Figure 6 This is a cross-sectional view of the rotor 300 and cover plate 400 provided in an embodiment of this application.

[0090] In one embodiment, such as Figure 3 and Figure 4 As shown, the generator 12 includes a housing 100, a stator 200, and a rotor 300. The housing 100 is used to fix the stator 200, and the central hole 210 of the stator 200 is used to accommodate the rotor 300. The rotor 300 is used to receive the power output from the engine 13. The rotation of the rotor 300 cuts the magnetic field lines, causing the windings of the stator 200 to generate an induced current.

[0091] The alternating current generated by the stator 200 is transmitted to the generator controller 11 through a three-phase connector connected to the stator winding. The generator controller 11 converts the alternating current into direct current through the power module to charge the power battery 30.

[0092] In one embodiment, the coolant channels of the generator 12 are used to deliver coolant to cool the stator 200 or rotor 300. In one embodiment, the coolant includes cooling oil or lubricating oil.

[0093] In one embodiment, the rotor 300 includes a plurality of fixing holes 310, which are spaced apart along the circumferential direction C of the generator 12. Each fixing hole 310 penetrates the rotor 300 along the axial direction O of the generator 12. Each fixing hole 310 is used to accommodate a fixing member 320, which is used to fix the rotor 300 and the crankshaft 1301 of the engine 13.

[0094] like Figure 5 and Figure 6 As shown, the rotor 300 includes multiple fixing holes 310, which are arranged at intervals along the circumferential direction C of the generator 12, making the fixed connection between the rotor 300 and the crankshaft 1301 of the engine 13 more secure and facilitating the rotor 300 to receive the power output from the crankshaft 1301.

[0095] In this embodiment, the fastener 320 is used to fix the rotor 300 and the crankshaft 1301 of the engine 13, so that the rotor 300 can be directly fixedly connected to the crankshaft 1301. The rotor 300 of the generator 12 realizes the flywheel function of the engine 13, reducing the use of the flywheel of the engine 13 and reducing production costs.

[0096] In one embodiment, the rotor 300 is used to fix the cover plate 400, which is distributed on one side 301 of the rotor 300 away from the crankshaft 1301 along the axial direction O of the generator 12. The cover plate 400 is used to seal one or more fixing holes 310.

[0097] In this embodiment, the cover plate 400 is fixed to the side 301 of the rotor 300 opposite to the crankshaft 1301 along the axial direction O of the generator 12. The cover plate 400 seals the fixing holes 310, thereby preventing the coolant in the housing 100 of the generator 12 from leaking out of the multiple fixing holes 310 of the rotor 300 to the outside of the housing 100 of the generator 12. It also prevents external moisture from entering the housing 100 of the generator 12 from the fixing holes 310, thereby improving the reliability and safety of the generator 12.

[0098] In one embodiment, such as Figure 5 and Figure 6 As shown, the rotor 300 includes a plurality of fixing holes 310, which are arranged at intervals along the circumferential direction C of the generator 12. Each fixing hole 310 penetrates the rotor 300 along the axial direction O of the generator 12. Each fixing hole 310 is used to accommodate a fixing member 320. The fixing member 320 is used to fix the rotor 300 and the crankshaft 1301 of the engine 13. The rotor 300 is used to fix a cover plate 400. The cover plate 400 is distributed on one side 301 of the rotor 300 away from the crankshaft 1301 along the axial direction O of the generator 12. The cover plate 400 is used to seal one or more fixing holes 310.

[0099] In this embodiment, the rotor 300 is directly fixedly connected to the crankshaft 1301 through multiple fixing holes 310 of the rotor 300. The rotor 300 of the generator 12 functions as the flywheel of the engine 13, which reduces the overall axial dimension of the engine 13 and the generator 12. Since the generator 12 cools the stator 200 or rotor 300 by supplying coolant through the coolant channel, the coolant in the cavity of the generator housing 100 is prone to leakage. A cover plate 400 is fixed on the side 301 of the rotor 300 opposite to the crankshaft 1301 along the axial direction O of the generator 12. The cover plate 400 seals the fixing holes 310 in the rotor 300 that are fixed to the crankshaft 1301, thereby preventing the coolant in the housing 100 of the generator 12 from leaking through the gap between the fixing holes 310 and the fixing parts 320, thus improving the reliability and safety of the generator 12.

[0100] In one embodiment, the rotor 300, along the axial direction O of the generator 12, on the side 301 opposite to the crankshaft 1301, is also used to fix the seal. The seal is distributed between the rotor 300 and the cover plate 400 along the axial direction O of the generator 12, and the seal is distributed around the fixing hole 310 along the circumferential direction C of the generator 12. The cover plate 400 is used to compress the seal to achieve a reliable seal of the fixing hole 310, improving the sealing effect of the cover plate 400 on the fixing hole 310.

[0101] In one embodiment, the seal is a sealing ring or a sealing gasket. One of the sides of the generator 12, the rotor 300 facing the cover plate 400 or the cover plate 400 facing the rotor 300, includes a groove for accommodating the seal. The other of the sides of the generator 12, the rotor 300 facing the cover plate 400 or the cover plate 400 facing the rotor 300, is used to contact and compress the seal. Assembly is simple and the cover plate 400 can easily seal the fixing hole 310.

[0102] In one embodiment, the sealant is a sealant that fills the gap between the rotor 300 and the cover plate 400. The sealant is distributed around each fixing hole 310 to facilitate a reliable seal between the cover plate 400 and the fixing holes 310.

[0103] In one embodiment, such as Figure 5 As shown, the cover plate 400 includes a plurality of first fixing holes 410, which are arranged at intervals along the circumferential direction C of the generator 12. The first fixing holes 410 are used to pass through the fixing member 320 to fix the cover plate 400 and the rotor 300. The first fixing holes 410 are distributed around the sealing member along the circumferential direction C of the generator 12. The first fixing holes 410 are used to fix the cover plate 400 and the rotor 300, and the fixing member in the first fixing hole 410 can apply a compressive force to the cover plate 400, improving the reliability of the sealing fixing holes 310 of the sealing member and enhancing the sealing effect of the cover plate 400 sealing the fixing holes 310.

[0104] In one embodiment, such as Figure 5 As shown, the multiple fixing holes 310 of the rotor 300 are sealed by a cover plate 400, which makes the assembly structure between the cover plate 400 and the rotor 300 simpler and simplifies the assembly process.

[0105] In one embodiment, the plurality of fixing holes 310 of the rotor 300 are sealed by a plurality of cover plates 400, thereby reducing the amount of material used in the cover plates 400 and reducing the overall weight of the cover plates 400 and the rotor 300.

[0106] In one embodiment, such as Figure 3As shown, the housing 100 is also used to house the mechanical pump 14, which is used to deliver coolant to the coolant channel of the generator 12, and the cover plate 400 is used to drive the rotor 300 and the mechanical pump 14.

[0107] In this embodiment, the cover plate 400 is used to drive the rotor 300 and the mechanical pump 14. The cover plate 400, which is used to seal the fixing hole 310 of the rotor 300, drives the mechanical pump 14, resulting in a higher degree of structural integration in the range extender powertrain 10. This facilitates a more compact structure and reduces the axial dimension occupied by the generator 12 housing 100. The reuse of the cover plate 400 for sealing the fixing hole 310 of the rotor 300 to drive the rotor 300 and the mechanical pump 14 also helps to increase the power density of the range extender powertrain 10.

[0108] In one embodiment, such as Figure 3 and Figure 5 As shown, the rotor 300 also includes an axial groove 330, which is distributed on one side 301 of the rotor 300 along the axial direction O of the generator 12, away from the crankshaft 1301. The groove opening 331 of the axial groove 330 is away from the crankshaft 1301 along the axial direction O of the generator 12, and the bottom 332 of the axial groove 330 is used to fix the cover plate 400. The housing 100 is also used to fix the mechanical pump 14, which is distributed on one side 100a of the housing 100 facing the axial groove 330. The outer diameter of the mechanical pump 14 is smaller than the inner diameter of the axial groove 330. The space between the cover plate 400 and the housing 100 along the axial direction O of the generator 12 is used to accommodate a portion 14a of the mechanical pump 14.

[0109] In this embodiment, the axial groove 330 is distributed on one side 301 of the rotor 300 away from the crankshaft 1301 along the axial direction O of the generator 12. The groove opening 331 of the axial groove 330 is away from the crankshaft 1301 along the axial direction O of the generator 12. The bottom 332 of the axial groove 330 is used to fix the cover plate 400, so that the cover plate 400 can be arranged using the axial groove 330 of the rotor 300. This makes the cover plate 400 not occupy additional axial space outside the rotor 300, which is beneficial to make the rotor 300 and the cover plate 400 as a whole smaller in size along the axial direction O of the generator 12, and also makes the axial direction O of the generator 12 smaller.

[0110] In this embodiment, the housing 100 is also used to fix the mechanical pump 14. The mechanical pump 14 is distributed on the side 100a of the housing 100 facing the axial groove 330. The outer diameter of the mechanical pump 14 is smaller than the inner diameter of the axial groove 330. The space between the cover plate 400 and the housing 100 along the axial direction O of the generator 12 is used to accommodate a part 14a of the mechanical pump 14. The cover plate 400 is fixed to the bottom 332 of the groove 330, so that the distance between the cover plate 400 and the housing 100 along the axial direction O of the generator 12 can be large, which makes it convenient for the mechanical pump 14 to be arranged in the space between the cover plate 400 and the housing 100 along the axial direction O of the generator 12 without interfering with the cover plate 400. The large gap between the cover plate 400 and the housing 100 along the axial direction O of the generator 12 allows for a larger axial dimension of the mechanical pump 14. The increased size of the mechanical pump 14 can improve the flow rate of the coolant delivered by the mechanical pump 14 to the coolant channel of the generator 12, thereby improving the cooling effect of the coolant channel of the generator 12 on the rotor 300 and stator 200 of the generator 12, and improving the stability and reliability of the generator 12.

[0111] In one embodiment, such as Figure 3 and Figure 6 As shown, the outer diameter of the cover plate 400 is smaller than the inner diameter of the axial groove 330. The cover plate 400 and the groove peripheral wall 333 of the axial groove 330 are arranged at intervals along the radial direction R of the generator 12, which facilitates the filling of adhesive between the cover plate 400 and the rotor 300 after the cover plate 400 is fixed to the rotor 300. The gap between the cover plate 400 and the groove peripheral wall 333 of the axial groove 330 needs to be sufficient to allow the dispensing instrument to be inserted to fill the sealant between the cover plate 400 and the bottom 332 of the axial groove 330.

[0112] Figure 7 This is another schematic diagram of the range extender powertrain 10 provided in the embodiments of this application.

[0113] In one embodiment, such as Figure 7 As shown, the cover plate 400 includes a first axial protrusion 420, which is distributed on the side of the cover plate 400 away from the rotor 300 along the axial direction O of the generator 12. The first axial protrusion 420 is used for transmission connection of the mechanical pump 14.

[0114] In this embodiment, the first axial protrusion 420 is distributed on the side of the cover plate 400 away from the rotor 300 along the axial direction O of the generator 12. The first axial protrusion 420 is used to drive the mechanical pump 14, so that the power of the rotor 300 can be output to the mechanical pump 14 through the first axial protrusion 420 of the cover plate 400. This makes the transmission structure of the cover plate 400 driving the rotor 300 and the mechanical pump 14 simpler and reduces the assembly difficulty.

[0115] Figure 8This is a partial exploded view of the range extender powertrain 10 provided in the embodiments of this application.

[0116] In one embodiment, such as Figure 3 and Figure 8 As shown, the generator 12 includes a drive shaft 500, which is used to drive the cover plate 400 and the mechanical pump 14. The drive shaft 500 is distributed between the cover plate 400 and the mechanical pump 14 along the axial direction O of the generator 12. One end 510 of the drive shaft 500 is used to embed into the cover plate 400, and the other end 520 of the drive shaft 500 is used to drive the mechanical pump 14 to rotate.

[0117] In this embodiment, the drive shaft 500 is distributed along the axial direction O of the generator 12 between the cover plate 400 and the mechanical pump 14. One end 510 of the drive shaft 500 is used to embed into the cover plate 400, and the other end 520 is used to drive the mechanical pump 14 to rotate, so that the cover plate 400 can transmit power to the mechanical pump 14 through the drive shaft 500. Using the drive shaft 500 as an intermediate transmission structure between the cover plate 400 and the mechanical pump 14 also helps to improve the reliability of the rotor 300 driving the mechanical pump 14.

[0118] In this embodiment, the drive shaft 500 is used as an intermediate transmission structure between the cover plate 400 and the mechanical pump 14, so that the axial length of the drive shaft 500 can be flexibly adjusted according to the axial distance between the cover plate 400 and the mechanical pump 14 to realize the transmission between the cover plate 400 and the mechanical pump 14.

[0119] In one embodiment, such as Figure 8 As shown, the first axial protrusion 420 of the cover plate 400 includes a groove 421. The opening of the groove 421 faces the drive shaft 500 along the axial direction O of the generator 12. One end 510 of the drive shaft 500 is used to be embedded in the groove 421 of the first axial protrusion 420. This facilitates the positioning of the drive shaft 500, making the assembly process between the drive shaft 500 and the cover plate 400 simpler and easier for the drive shaft 500 to receive power from the cover plate 400. The distance between the first axial protrusion 420 and the mechanical pump 14 along the axial direction O of the generator 12 is small. The drive shaft 500 is embedded in the groove 421 of the first axial protrusion 420, which allows the axial length of the drive shaft 500 to be shortened, improving the reliability of the drive shaft 500 in connecting the cover plate 400 and the mechanical pump 14.

[0120] In one embodiment, such as Figure 3As shown, the axial length of the cover plate 400 along the axial direction of the generator 12 is less than the groove depth of the axial groove 330. The drive shaft 500 is used to drive the cover plate 400 and the mechanical pump 14. The axial groove 330 of the rotor 300 is used to accommodate a part of the drive shaft 500, so that the drive shaft 500 can be arranged using part of the axial space of the rotor 300, which is beneficial to make the rotor 300 and the mechanical pump 14 more compactly arranged along the axial direction O of the generator 12.

[0121] In one embodiment, the axial groove 330 of the rotor 300 is used to accommodate a part of the drive shaft 500 and a part of the mechanical pump 14, so that the mechanical pump 14 can be arranged using part of the axial space of the rotor 300, thereby making it easier to increase the axial dimension of the mechanical pump 14. This is beneficial to increasing the flow rate of the coolant delivered by the mechanical pump 14 to the coolant channel of the generator 12, improving the cooling effect of the coolant channel of the generator 12 on the rotor 300 and stator 200 of the generator 12, and improving the stability and reliability of the generator 12.

[0122] Figure 9 yes Figure 6 A partial enlarged view of the M1 portion of the rotor 300 and cover plate 400.

[0123] In one embodiment, such as Figure 6 and Figure 9 As shown, each fixing hole 310 of the rotor 300 includes a first section 311 and a second section 312. Along the axial direction of the generator 12, the first section 311 is closer to the cover plate 400 than the second section 312. The inner diameter of the first section 311 is larger than the inner diameter of the second section 312. The first section 311 is used to accommodate the fastening end 321 of the fixing member 320, such as... Figure 3 As shown, the second segment 312 is used to pass through the fixing member 320 and extend into the fixing hole 1302 of the crankshaft 1301, as... Figure 9 As shown, the axial length of the first segment 311 along the axial direction O of the generator 12 is greater than the axial length of the fastening end 321 of the fastener 320 accommodated by the first segment 311.

[0124] In the embodiments of this application, such as Figure 9As shown, the axial length of the first segment 311 along the axial direction O of the generator 12 is denoted as L1, and the axial length of the fastening end 321 of the fastener 320 accommodated in the first segment 311 is denoted as L2. L1 > L2, and L1 is larger, so that the fastener 320 can be completely accommodated in the fixing hole 310, thus ensuring that the fastener 320 does not obstruct the mounting of the cover plate 400 to the sealing fixing hole 310 of the rotor 300. It also results in a smaller axial gap between the cover plate 400 and the fixing hole 310, making it easier to seal the fixing hole 310 with the cover plate 400. Furthermore, it facilitates making the portion of the cover plate 400 covering the fixing hole 310 flat, simplifying the manufacturing process of the cover plate 400. A larger L1 also allows for weight reduction of the rotor 300.

[0125] In one embodiment, when sealant is used to fill the gap between the rotor 300 and the cover plate 400 along the axial direction O of the generator 12 to seal the fixing hole 310, the axial length of the first segment 311 along the axial direction O of the generator 12 is greater than the axial length of the fastening end 321 of the fixing member 320 accommodated by the first segment 311, which can make the gap between the rotor 300 and the cover plate 400 smaller and easier to seal with sealant.

[0126] In one embodiment, such as Figure 9 As shown, the inner diameter of the first section 311 of each fixing hole 310 is larger than the outer diameter of the fastening end 321 of the fixing member 320. Making the inner diameter of the first section 311 larger can reduce the weight of the rotor 300.

[0127] Figure 10 This is a schematic diagram of a rotor 300 provided in an embodiment of this application.

[0128] In one embodiment, such as Figure 3 and Figure 10 As shown, the rotor 300 also includes a first receiving groove 340, which is distributed on one side 302 of the rotor 300 facing the crankshaft 1301. The groove opening 341 of the first receiving groove 340 faces the crankshaft 1301 along the axial direction O of the generator 12. A plurality of fixing holes 310 are distributed around the first receiving groove 340. The first receiving groove 340 is used to accommodate the insertion of the crankshaft 1301.

[0129] In this embodiment, the slot 341 of the first receiving groove 340 of the rotor 300 faces the crankshaft 1301 along the axial direction O of the generator 12. A plurality of fixing holes 310 are distributed around the first receiving groove 340. The first receiving groove 340 is used to accommodate the insertion of the crankshaft 1301, so that the rotor 300 and the crankshaft 1301 can be positioned through the first receiving groove 340 of the rotor 300 before the fixing member 320 passes through the fixing hole 310 to fix the rotor 300 and the crankshaft 1301, which facilitates the direct fixing of the rotor 300 and the crankshaft 1301.

[0130] In this embodiment, the rotor 300 includes a first receiving groove 340, and the rotor 300 can also be made lighter.

[0131] In one embodiment, such as Figure 3 , Figure 5 and Figure 6 As shown, the rotor 300 also includes a second receiving groove 350, which is distributed on one side 301 of the rotor 300 away from the crankshaft 1301. The groove opening 351 of the second receiving groove 350 is away from the crankshaft 1301 along the axial direction O of the generator 12. A plurality of fixing holes 310 are distributed around the second receiving groove 350. The second receiving groove 350 is used to accommodate the embedding of the cover plate 400.

[0132] In this embodiment, the slot 351 of the second receiving groove 350 is away from the crankshaft 1301 along the axial direction O of the generator 12, and a plurality of fixing holes 310 are distributed around the second receiving groove 350. The second receiving groove 350 is used to accommodate the embedding of the cover plate 400, so that after the rotor 300 is fixed to the crankshaft 1301, the cover plate 400 can be positioned through the second receiving groove 350 of the rotor 300, simplifying the assembly process of fixing the cover plate 400 to the rotor 300.

[0133] In this embodiment, multiple fixing holes 310 are distributed around the second receiving groove 350, which is beneficial to seal the opening 351 of the second receiving groove 350 when the cover plate 400 seals the fixing holes 310, thus preventing the coolant in the housing 100 of the generator 12 from leaking from the second receiving groove 350.

[0134] In this embodiment, the rotor 300 includes a second receiving groove 350, and the rotor 300 can also be made lighter.

[0135] In one embodiment, such as Figure 6 As shown, the cover plate 400 includes a third axial protrusion 430, which is distributed on the side of the cover plate 400 facing the rotor 300 along the axial direction O of the generator 12. The third axial protrusion 430 is used to be embedded in the second receiving groove 350.

[0136] In one embodiment, such as Figure 3 , Figure 5 and Figure 6As shown, the rotor 300 also includes a weight-reducing through-hole 360, which extends along the axial direction O of the generator 12 through the bottom 342 of the first receiving groove 340 and the bottom 352 of the second receiving groove 350. The cover plate 400 is also used to seal the opening 351 of the second receiving groove 350. The weight-reducing through-hole 360 ​​connects the first receiving groove 340 and the second receiving groove 350, facilitating the simultaneous machining of the first receiving groove 340 and the second receiving groove 350, thus simplifying the machining process of the rotor 300. This allows the rotor 300 to be positioned with the crankshaft 1301 through the first receiving groove 340, and the cover plate 400 and the rotor 300 to be positioned through the second receiving groove 350, reducing assembly difficulty. Furthermore, the rotor 300 can be weight-reduced through the first receiving groove 340, the second receiving groove 350, and the weight-reducing through-hole 360.

[0137] Figure 11 This is another schematic diagram of the rotor 300 provided in the embodiments of this application.

[0138] In one embodiment, such as Figure 11 As shown, the rotor 300 includes a first through hole 370, which extends through the rotor 300 along the axial direction O of the generator 12. One opening 371 of the first through hole 370 along the axial direction O of the generator 12, facing the crankshaft 1301, is used to accommodate the insertion of the crankshaft 1301. Another opening 372 of the first through hole 370 along the axial direction O of the generator 12, away from the crankshaft 1301, is used to accommodate the insertion of a cover plate 400. The cover plate 400 seals the other opening 372 of the first through hole 370. This facilitates the positioning of the rotor 300 and the crankshaft 1301, as well as the positioning of the cover plate 400 and the rotor 300, simplifying the assembly process. The machining process of the first through hole 370 is simple. The first through hole 370 can also reduce the weight of the rotor 300.

[0139] In this embodiment, the cover plate 400 is used to seal another opening 372 of the first through hole 370, thereby preventing coolant in the housing 100 of the generator 12 from leaking from the first through hole 370.

[0140] In one embodiment, such as Figure 11 As shown, the first through hole 370 of the rotor 300 includes a third section 373 and a fourth section 374. Along the axial direction of the generator 12, the third section 373 is closer to the crankshaft 1301 than the fourth section 374. The inner diameter of the third section 373 is larger than the inner diameter of the fourth section 374. The third section 373 is used to accommodate the insertion of the crankshaft 1301, and the fourth section 374 is used to accommodate the insertion of the cover plate 400.

[0141] In this embodiment, the inner diameter of the third segment 373 is relatively large, which facilitates the insertion of the crankshaft 1301 with a larger outer diameter into the third segment 373. The inner diameter of the fourth segment 374 is relatively small, which allows the cover plate 400 to be inserted into the fourth segment 374 to seal a smaller outer diameter, thereby reducing the risk of coolant leakage from the fourth segment 374 of the first through hole 370.

[0142] In one embodiment, such as Figure 4 As shown, the housing 100 of the generator 12 includes a first housing 110 and a second housing 120. The first housing 110 is used to fix and connect the housing 1303 of the engine 13. The first housing 110 has a slot-shaped structure. The slot 111 of the first housing 110 faces away from the engine 13 along the axial direction O of the generator 12. The slot 111 of the first housing 110 is used to accommodate the insertion of the stator 200. The central hole 210 of the stator 200 is used to accommodate the insertion of the rotor 300. The second housing 120 is used to surround the slot 111 of the first housing 110.

[0143] In this embodiment, the first housing 110 is used to fix the housing 1303 of the engine 13. The first housing 110 has a slot-shaped structure. The slot 111 of the first housing 110 faces away from the engine 13 along the axial direction O of the generator 12. The slot 111 of the first housing 110 is used to accommodate the insertion of the stator 200. The central hole 210 of the stator 200 is used to accommodate the insertion of the rotor 300. The rotor 300 is used to fix the cover plate 400. The cover plate 400 is distributed on the side 301 of the rotor 300 facing away from the crankshaft 1301 along the axial direction O of the generator 12. This allows the stator 200, rotor 300 and cover plate 400 to be assembled from the slot 111 of the first housing 110, realizing unidirectional assembly and simplifying the assembly process.

[0144] In this embodiment of the application, the second housing 120 is used to enclose the slot 111 of the first housing 110, which can prevent the coolant in the housing 100 of the generator 12 from leaking from the slot 111 of the first housing 110.

[0145] In one embodiment, such as Figure 3 and Figure 4 As shown, the mating surface of the first housing 110 and the mating surface of the second housing 120 are sealed with sealant.

[0146] In one embodiment, such as Figure 3 , Figure 4 and Figure 10As shown, the slot 111 of the first housing 110 faces away from the engine 13 along the axial direction O of the generator 12, and the slot 341 of the first receiving groove 340 faces the crankshaft 1301 along the axial direction O of the generator 12. The orientation of the slot 111 of the first housing 110 is opposite to that of the slot 341 of the first receiving groove 340. This allows the rotor 300 to be assembled into the first housing 110 from the slot 111 on the side of the first housing 110 facing away from the engine 13 after the first housing 110 is fixed to the housing 1303 of the engine 13. At the same time, the first receiving groove 340 faces the crankshaft 1301. When the first receiving groove 340 accommodates the insertion of the crankshaft 1301, the rotor 300 is positioned, which facilitates a simplified assembly process for the rotor 300.

[0147] In one embodiment, such as Figures 3 to 5 As shown, the slot 111 of the first housing 110 faces away from the engine 13 along the axial direction O of the generator 12, and the slot 351 of the second receiving groove 350 faces away from the crankshaft 1301 along the axial direction O of the generator 12. The slot 111 of the first housing 110 faces the same direction as the slot 351 of the second receiving groove 350. This allows the rotor 300 to be installed from the slot 111 direction of the first housing 110, and the cover plate 400 to be inserted into the second receiving groove 350 of the rotor 300 from the slot 111 direction of the first housing 110. This allows the stator 200 of the generator 12, the rotor 300 of the generator 12, and the cover plate 400 to be assembled sequentially from the slot 111 direction of the first housing 110, simplifying the assembly process.

[0148] In one embodiment, such as Figure 3 and Figure 4 As shown, the second housing 120 is used to fix the mechanical pump 14, which is distributed on one side of the second housing 120 facing the axial groove 330 of the rotor 300. The space between the cover plate 400 and the second housing 120 along the axial direction of the generator 12 is used to accommodate a portion 14a of the mechanical pump 14. This allows the second housing 120 to enclose the slot 111 of the first housing 110 while enabling the mechanical pump 14 to be assembled with the first axial protrusion 420 of the cover plate 400 or with the drive shaft 500 of the generator 12, simplifying the assembly process.

[0149] Figure 12 This is a schematic diagram of a first housing 110 provided in an embodiment of this application. Figure 13 yes Figure 3 A partial enlarged view of the M2 section of the range extender powertrain 10.

[0150] In one embodiment, such as Figure 3 , Figure 12 and Figure 13As shown, the groove bottom 112 of the first housing 110 includes an axial through hole 1120, the rotor 300 includes a second axial protrusion 380, the fixing hole 310 passes through the second axial protrusion 380 along the axial direction O of the generator 12, the second axial protrusion 380 is distributed on the side 302 of the rotor 300 facing the crankshaft 1301, and the gap between the hole wall 1121 of the axial through hole 1120 and the second axial protrusion 380 along the radial direction R of the generator 12 is used to accommodate the seal 600.

[0151] In this embodiment, since the first housing 110 is fixedly connected to the housing 1303 of the engine 13, the rotor 300 needs to be assembled from the slot 111 of the first housing 110 away from the engine 13. The slot bottom 112 of the first housing 110 includes an axial through hole 1120, and the rotor 300 includes a second axial protrusion 380. The fixing hole 310 passes through the second axial protrusion 380 along the axial direction O of the generator 12, so that the second axial protrusion 380 of the rotor 300 can pass into the axial through hole 1120 to achieve a fixed connection with the crankshaft 1301.

[0152] In this embodiment, the gap between the hole wall 1121 of the axial through hole 1120 and the second axial protrusion 380 along the radial direction R of the generator 12 is used to accommodate the seal 600, so that the second axial protrusion 380 of the rotor 300 and the hole wall 1121 of the axial through hole 1120 are radially sealed by the seal 600, thereby preventing the coolant in the housing 100 of the generator 12 from leaking from the axial through hole 1120 of the first housing 110.

[0153] In this embodiment, the second axial protrusion 380 penetrates the axial through hole 1120 of the first housing 110, and the fixing hole 310 passes through the second axial protrusion 380 along the axial direction O of the generator 12. The fixing hole 310 is sealed by a cover plate 400, so that the cover plate 400 can achieve axial sealing with the rotor 300, thereby preventing the coolant in the housing 100 of the generator 12 from leaking from the fixing hole 310 to the outside of the axial through hole 1120 of the first housing 110.

[0154] In this embodiment, the sealing element 600 is used to seal the housing 100 of the generator 12 and the rotor 300, and the cover plate 400 is used to seal the fixing hole 310. The two seals isolate the inner cavity of the housing 100 of the generator 12 from the outside, thereby improving the sealing reliability of the housing 100 of the generator 12.

[0155] In one embodiment, such as Figure 13As shown, the hole wall 1121 of the axial through hole 1120 is used to fix the seal 600. The seal 600 and the second axial protrusion 380 of the rotor 300 are dynamically sealed, so that the second axial protrusion 380 of the rotor 300 can be sealed with the first housing 110 without affecting the rotation of the rotor 300.

[0156] In one embodiment, such as Figure 3 As shown, the second axial protrusion 380 includes a first receiving groove 340, which is distributed on the side of the second axial protrusion 380 facing the crankshaft 1301, so that the crankshaft 1301 can be embedded in the first receiving groove 340 of the second axial protrusion 380, thereby reducing the weight of the second axial protrusion 380.

[0157] In one embodiment, such as Figure 3 and Figure 13 As shown, the hole wall 1121 of the axial through hole 1120 protrudes from the inner side of the first housing 110 along the axial direction O of the generator 12, and the rotor 300 includes an annular groove 390, as shown. Figure 10 As shown, the annular groove 390 is distributed on the side of the rotor 300 facing the engine 13, and the annular groove 390 is used to avoid the hole wall 1121 of the axial through hole 1120.

[0158] In this embodiment, the hole wall 1121 of the axial through hole 1120 protrudes from the inner side of the first housing 110 along the axial direction O of the generator 12, which can make the hole wall 1121 of the axial through hole 1120 have a larger axial dimension, so that the hole wall 1121 of the axial through hole 1120 can fix the sealing member 600 and the second axial protrusion 380 of the rotor 300 to achieve sealing.

[0159] In this embodiment, the rotor 300 includes an annular groove 390, which can reduce the weight of the rotor 300.

[0160] In this embodiment, the annular groove 390 is distributed on the side of the rotor 300 facing the engine 13. The annular groove 390 is used to avoid the hole wall 1121 of the axial through hole 1120, so that the hole wall 1121 of the axial through hole 1120 can be arranged more compactly with the rotor 300 along the axial direction O of the generator 12. It can also make the seal 600 between the hole wall 1121 of the axial through hole 1120 and the second axial protrusion 380 arranged using part of the axial space of the annular groove 390, which is beneficial to make the generator 12 structure compact and occupy a small axial dimension.

[0161] In one embodiment, such as Figure 13As shown, the hole wall 1121 of the axial through hole 1120 protrudes from the side of the first housing 110 facing the engine 13 along the axial direction O of the generator 12, and the depth of the groove bottom 112 of the first housing 110 recessed towards the center hole 210 of the stator 200 along the axial direction O of the generator 12 is equal to or greater than the dimension of the hole wall 1121 of the axial through hole 1120 protruding from the outside of the first housing 110.

[0162] In this embodiment, the hole wall 1121 of the axial through hole 1120 protrudes from the side of the first housing 110 facing the engine 13 along the axial direction O of the generator 12, so that the hole wall 1121 of the axial through hole 1120 has a larger axial dimension, which makes it easier for the hole wall 1121 of the axial through hole 1120 to fix the sealing member 600 and the second axial protrusion 380 of the rotor 300 to achieve sealing.

[0163] In the embodiments of this application, such as Figure 13 As shown, the depth of the recess of the groove bottom 112 of the first housing 110 along the axial direction O of the generator 12 towards the center hole 210 of the stator 200 is denoted as L3. The dimension of the hole wall 1121 of the axial through hole 1120 protruding outward from the first housing 110 is denoted as L4. L3 ≥ L4. A larger L3 can avoid increasing the axial dimension of the first housing 110 after the hole wall 1121 of the axial through hole 1120 protrudes outward from the side of the first housing 110 facing the engine 13, which is beneficial to make the axial dimension of the housing 100 of the generator 12 smaller. A larger L3 can also avoid the sealing structure between the housing 1303 of the engine 13 and the crankshaft 1301, which can make the overall axial dimension of the generator 12 and the engine 13 smaller. It can also achieve radial sealing between the rotor 300 and the first housing 110 of the generator 12 without interfering with the sealing between the housing 1303 of the engine 13 and the crankshaft 1301.

[0164] In one embodiment, such as Figure 3 and Figure 6 As shown, the rotor 300 includes a rotor support 300a and a rotor core 300b. The rotor support 300a is used to directly fix the crankshaft 1301 and to fix the rotor core 300b. The fixing hole 310 passes through the rotor support 300a along the axial direction O of the generator 12.

[0165] In this embodiment, the rotor bracket 300a is used to directly fix the crankshaft 1301 and to fix the rotor core 300b, so that the rotor 300 can be fixedly connected to the crankshaft 1301 through the rotor bracket 300a.

[0166] In this embodiment, the fixing hole 310 passes through the rotor support 300a along the axial direction O of the generator 12, and the cover plate 400 is distributed on the side of the rotor support 300a away from the crankshaft 1301 along the axial direction O of the generator 12. The cover plate 400 seals the fixing hole 310 on the rotor support 300a, so that the coolant in the housing 100 of the generator 12 will not leak from the fixing hole 310 of the rotor support 300a to the outside of the housing 100.

[0167] In one embodiment, such as Figure 6 As shown, the axial grooves 330 for fixing the cover plate 400 are distributed on the side of the rotor support 300a away from the crankshaft 1301 along the axial direction O of the generator 12. The axial grooves 330 are formed directly by the rotor support 300a.

[0168] In one embodiment, the axial groove 330 is formed by the rotor support 300a and the rotor core 300b together.

[0169] The generator, range extender powertrain, and electric vehicle provided in the embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and embodiments of this application. The description of the embodiments above is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in specific embodiments and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A generator, characterized in that, The generator is used to drive the engine of a range-extended electric vehicle. The generator housing houses the generator stator and rotor. The generator coolant channels deliver coolant to cool the stator or rotor. The rotor includes a plurality of fixing holes, which are arranged at intervals along the circumference of the generator. Each fixing hole penetrates the rotor along the axial direction of the generator. Each fixing hole is used to accommodate a fixing member, which is used to fix the rotor and the crankshaft of the engine. The rotor is used to fix a cover plate, which is distributed on the side of the rotor away from the crankshaft along the axial direction of the generator, and the cover plate is used to seal one or more of the fixing holes.

2. The generator according to claim 1, characterized in that, The housing also houses a mechanical pump for supplying coolant to the coolant channels of the generator, and the cover plate serves as a drive connection between the rotor and the mechanical pump.

3. The generator according to claim 2, characterized in that, The rotor further includes axial grooves distributed on the side of the rotor facing away from the crankshaft along the axial direction of the generator. The opening of the axial groove faces away from the crankshaft along the axial direction of the generator, and the bottom of the axial groove is used to fix the cover plate. The housing is also used to fix a mechanical pump, which is located on the side of the housing facing the axial groove. The outer diameter of the mechanical pump is smaller than the inner diameter of the axial groove. The space between the cover plate and the housing along the axis of the generator is used to accommodate a portion of the mechanical pump.

4. The generator according to any one of claims 2-3, characterized in that, The cover plate includes a first axial protrusion, which is distributed on the side of the cover plate opposite to the rotor along the axial direction of the generator. The first axial protrusion is used for drive connection to the mechanical pump.

5. The generator according to any one of claims 2-4, characterized in that, The generator includes a drive shaft for driving the cover plate and the mechanical pump. The drive shaft is distributed between the cover plate and the mechanical pump along the axial direction of the generator. One end of the drive shaft is used to embed into the cover plate, and the other end of the drive shaft is used to drive the mechanical pump to rotate.

6. The generator according to any one of claims 1-5, characterized in that, Each of the mounting holes of the rotor includes a first segment and a second segment. Along the axial direction of the generator, the first segment is closer to the cover plate than the second segment. The inner diameter of the first segment is larger than the inner diameter of the second segment. The first segment is used to accommodate the fastening end of the fastener. The second segment is used to extend through the mounting hole of the fastener into the crankshaft. Along the axial direction of the generator, the axial length of the first segment is greater than the axial length of the fastening end of the fastener accommodated by the first segment.

7. The generator according to any one of claims 1-6, characterized in that, The rotor also includes a first receiving groove, which is distributed on the side of the rotor facing the crankshaft. The opening of the first receiving groove faces the crankshaft along the axial direction of the generator. The plurality of fixing holes are distributed around the first receiving groove, which is used to accommodate the insertion of the crankshaft.

8. The generator according to any one of claims 1-7, characterized in that, The rotor also includes a second receiving groove, which is distributed on the side of the rotor away from the crankshaft. The opening of the second receiving groove is away from the crankshaft along the axial direction of the generator. The plurality of fixing holes are distributed around the second receiving groove, which is used to accommodate the embedding of the cover plate.

9. The generator according to any one of claims 1-8, characterized in that, The generator housing includes a first housing and a second housing. The first housing is used to fix the engine housing. The first housing has a slot-shaped structure. The slot of the first housing faces away from the engine along the axial direction of the generator. The slot of the first housing is used to accommodate the stator. The central hole of the stator is used to accommodate the rotor. The second housing is used to surround the slot of the first housing.

10. The generator according to claim 9, characterized in that, The bottom of the first housing includes an axial through hole, the rotor includes a second axial protrusion, the fixing hole passes through the second axial protrusion along the axial direction of the generator, the second axial protrusion is distributed on the side of the rotor facing the crankshaft, and the gap between the hole wall of the axial through hole and the second axial protrusion along the radial direction of the generator is used to accommodate a seal.

11. The generator according to claim 10, characterized in that, The wall of the axial through hole protrudes from the inner side of the first housing along the axial direction of the generator. The rotor includes an annular groove distributed on the side of the rotor facing the engine. The annular groove is used to avoid the wall of the axial through hole.

12. The generator according to claim 10 or 11, characterized in that, The wall of the axial through hole protrudes from the side of the first housing facing the engine along the axial direction of the generator, and the depth of the groove bottom of the first housing recessed towards the center hole of the stator along the axial direction of the generator is equal to or greater than the dimension of the wall of the axial through hole protruding from the outside of the first housing.

13. The generator according to any one of claims 1-12, characterized in that, The rotor includes a rotor support and a rotor core. The rotor support is used to directly fix the crankshaft and to fix the rotor core. The fixing hole passes through the rotor support along the axial direction of the generator.

14. A range-extending powertrain, characterized in that, The range extender powertrain includes a generator controller and a generator as described in any one of claims 1-13, wherein the generator controller is used to receive alternating current generated by the generator and to output direct current to charge the power battery of the electric vehicle.

15. An electric vehicle, characterized in that, The electric vehicle includes a power battery and a range-extending powertrain as described in claim 14, the range-extending powertrain being used to charge the power battery.

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