Novel extended-range engine general arrangement structure

Abstract

The invention discloses a novel extended-range engine general arrangement structure and belongs to the technical field of engines. An engine body is of an inverted type, a front end assembly, an exhaust side assembly, an air inlet side assembly, a rear end assembly and a bottom assembly are correspondingly arranged in all directions of the engine body, and cooling liquid, engine oil, pressurized gas and waste gas circulation pipelines are arranged among the assemblies. The body is integrated with a cylinder cover exhaust manifold water jacket and is of a low-pressure EGR structure for taking gas behind a turbine and in front of a three-way catalyst, the low-pressure cooling EGR assembly is distributed at the high point of the exhaust side of a cylinder cover, a cooling liquid water taking point at the position of the cylinder cover is used for cooling, and the gas inlet end and the gas outlet end of the low-pressure cooling EGR assembly are communicated with a gas outlet of the turbine end of a turbocharger and the gas inlet end of a gas compressor respectively. A TVD wheel assembly wrapped by a synchronous chain housing assembly is arranged in the body, and the air cylinder body is communicated with the cylinder cover water jacket through a cooling liquid pipeline. Through layout and structure optimization, compact cabin adaptation of the engine is achieved, the NVH performance of the whole engine is improved, all-working-condition stable work of all systems is guaranteed, meanwhile, energy-saving and environment-friendly operation is achieved, and the comprehensive use performance of the range extending engine is overall improved.

Description

Technical Field

[0001] This invention belongs to the field of engine technology, specifically a novel overall layout structure for a range-extending engine. Background Technology

[0002] In today's automotive industry, electric vehicles are being used more and more widely, but they suffer from range anxiety, strong dependence on charging stations, and significant range reduction in low-temperature conditions; traditional fuel vehicles, on the other hand, have drawbacks such as high energy consumption and failure to meet emission standards.

[0003] To simultaneously meet the pure electric driving experience and the power requirements for long-distance travel, range-extended engines have emerged. The overall layout of the engine directly affects its adaptability, energy consumption and emission performance. Therefore, it is urgent to develop a compact and highly adaptable overall layout for range-extended engines. Summary of the Invention

[0004] To address the problems existing in the background art, the present invention provides a novel overall layout structure for a range-extending engine.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a novel range-extending engine overall layout structure, including an engine body; the engine body is of an inverted type and is inclined towards the exhaust side at an angle of 0°~10°; the upper end of the cylinder block assembly on the engine body is sealed and fixedly mounted with a cylinder head; the water jacket of the cylinder block assembly and the water jacket of the cylinder head are connected through a coolant flow pipe; the front end, exhaust side, intake side, rear end, and bottom of the engine body are respectively provided with a front end assembly, an exhaust side assembly, an intake side assembly, a rear end assembly, and a bottom assembly; the front end assembly, exhaust side assembly, intake side assembly, and rear end assembly are respectively arranged with a front end assembly, an exhaust side assembly, an intake side assembly, a rear end assembly, and a bottom assembly. Coolant flow lines, oil flow lines, boost gas flow lines, and exhaust gas flow lines are provided between the end components and the bottom components. The engine block integrates a cylinder head exhaust manifold water jacket and is a low-pressure EGR structure with intake air from the turbocharger and intake air from the three-way catalytic converter. The intake end of the low-pressure cooling EGR assembly of the exhaust-side component is connected to the turbine end outlet of the turbocharger assembly and the exhaust gas line upstream of the three-way catalytic converter. The outlet end of the low-pressure cooling EGR assembly is connected to the compressor intake end of the turbocharger assembly through the exhaust gas flow line. The engine block has a built-in TVD wheel assembly (Torsional). Vibration Damper (TVD) assembly is built into the inner cavity of the synchronous chain cover assembly. A coolant intake point is provided at the high point of the exhaust side of the cylinder head. The coolant intake point is connected to the cylinder head water jacket and is connected to the coolant inlet of the low-pressure cooling EGR assembly through the coolant flow pipe. The low-pressure cooling EGR assembly is located at the high point of the exhaust side of the cylinder head.

[0006] The engine body is a fuel-supply type range extender engine with a rated displacement of 2.0L; a valve cover and oil filler cap assembly is fixed above the cylinder head, and an ignition coil is arranged on the valve cover and oil filler cap assembly; the front end assembly includes an oil dipstick guide, an oil dipstick, an electromagnetic coil, a synchronizer chain cover assembly, and an engine front mount. The engine front mount and the synchronizing chain cover assembly are both mounted on the front end of the engine body. The electromagnetic coil is arranged on the upper part of the synchronizing chain cover assembly, and the oil dipstick guide is arranged on the lower part of the synchronizing chain cover assembly. The oil dipstick is slidably inserted inside the oil dipstick guide.

[0007] The bottom assembly includes an oil pan assembly, an oil filter, and a fully variable displacement oil pump; The oil pan assembly is sealed and fixed to the bottom of the cylinder block assembly. The oil filter is fixed to the rear end of the oil pan assembly. The oil inlet of the fully variable displacement oil pump is connected to the oil outlet of the oil pan assembly through an oil flow pipeline. The oil outlet of the fully variable displacement oil pump is connected to the oil inlet of the oil filter through an oil flow pipeline. The oil outlet of the oil filter is connected to the main oil passage inlet of the engine block through an oil flow pipeline. The main oil passage of the engine block is connected to the oil inlet of the oil cooler assembly through an oil flow pipeline. The oil return end of the oil cooler assembly is connected to the oil inlet of the oil pan assembly through an oil flow pipeline.

[0008] The exhaust-side assembly includes an inlet pipe and O-ring assembly, an inlet adapter assembly, a low-pressure cooling EGR assembly, a turbocharger oil inlet pipe assembly, a turbocharger oil return pipe assembly, a turbocharger water inlet hose assembly, a turbocharger assembly, a turbocharger inlet and outlet water steel pipe assembly, an EGR water outlet hose assembly, and a turbocharger water outlet hose assembly. The water inlet pipe and O-ring assembly, water inlet adapter assembly, low-pressure cooling EGR assembly, turbocharger oil inlet pipe assembly, turbocharger oil return pipe assembly, turbocharger water inlet hose assembly, turbocharger assembly, turbocharger inlet and outlet water steel pipe assembly, EGR water outlet hose assembly, and turbocharger water outlet hose assembly are all assembled on the exhaust side of the engine block. The low-pressure cooling EGR assembly is assembled at the high point of the cylinder head exhaust side, and the turbocharger assembly is assembled in the middle of the engine block exhaust side. The water inlet adapter assembly and water inlet pipe and O-ring assembly are arranged at the lower end of the engine block exhaust side. The exhaust manifold water jacket integrated with the cylinder head is provided with a cooling EGR water inlet connector, which is connected to the coolant inlet of the low-pressure cooling EGR assembly.

[0009] The oil outlet of the turbocharger inlet pipe assembly and the oil inlet of the turbocharger return pipe assembly are both connected to the turbocharger assembly. The turbocharger inlet and outlet water pipe assemblies are respectively connected to the coolant inlet and coolant outlet of the turbocharger assembly. The water outlet of the turbocharger inlet hose assembly and the water inlet of the turbocharger outlet hose assembly are both connected to the turbocharger inlet and outlet water pipe assemblies. The water inlet of the EGR outlet hose assembly is connected to the coolant outlet of the low-pressure cooling EGR assembly. The oil return end of the turbocharger return pipe assembly is connected to the oil pan assembly through an oil flow pipeline.

[0010] The intake-side assembly includes an intake hose assembly, an electronic main water pump assembly, an oil cooler assembly, an oil cooler outlet hose assembly, an oil cooler inlet hose assembly, an intake manifold assembly, a water-to-air intercooler assembly, an electronic throttle body, a turbocharger outlet pipe, an intake pressure relief valve, a thermostat, and a housing assembly. The inlet hose assembly, electronic main water pump assembly, oil cooler assembly, oil cooler outlet hose assembly, oil cooler inlet hose assembly, intake manifold assembly, water-to-intercooler assembly, electronic throttle body, turbocharger outlet pipe, intake pressure relief valve, thermostat and housing assembly are all mounted on the intake side of the engine block. The coolant outlet of the thermostat and housing assembly is connected to the inlet of the vehicle radiator via a coolant flow pipe. The intake end of the intake pressure relief valve is connected to the turbocharger outlet. The pipes are connected, the outlet end of the intake pressure relief valve is connected to the intake front end pipe of the turbocharger assembly, the inlet end of the turbocharger outlet pipe is connected to the compressor outlet end of the turbocharger assembly, the outlet end of the turbocharger outlet pipe is connected to the pressurized gas inlet end of the water-to-air intercooler assembly, the pressurized gas outlet end of the water-to-air intercooler assembly is connected to the inlet end of the electronic throttle body, and the outlet end of the electronic throttle body is connected to the pressurized gas inlet end of the intake manifold assembly.

[0011] The inlet of the electronic main water pump assembly is connected to the vehicle radiator, and the outlet of the electronic main water pump assembly is connected to the inlet end of the inlet hose assembly. The outlet end of the inlet hose assembly is connected to the inlet end of the inlet pipe and O-ring assembly. The outlet end of the inlet pipe and O-ring assembly is connected to the inlet end of the inlet adapter assembly. The inlet pipe and O-ring assembly is also connected to the inlet end of the turbocharger inlet hose assembly and the inlet end of the oil cooler inlet hose assembly. The outlet end of the oil cooler inlet hose assembly is connected to the coolant inlet end of the oil cooler assembly, and the inlet end of the oil cooler outlet hose assembly is connected to the coolant outlet end of the oil cooler assembly.

[0012] The rear-end components include a torsion pipe assembly, an intake mixing valve assembly, an oil-gas desorption pipe assembly, a heater inlet and outlet water steel pipe assembly, a small circulation connecting hose assembly, a heater outlet water hose assembly, a drive disc assembly, and a torsional damper assembly. The curved pipe assembly, intake mixing valve assembly, and fuel-air desorption pipe assembly are mounted on the upper rear end of the engine block. The outlet of the curved pipe assembly is connected to the intake end of the intake mixing valve assembly, and the outlet of the intake mixing valve assembly is connected to the engine intake system. The intake end of the fuel-air desorption pipe assembly is connected to the vehicle fuel system, and the outlet of the fuel-air desorption pipe assembly is connected to the engine intake system. The heater inlet and outlet water pipe assembly is mounted on the middle rear end of the engine block. The small circulation connecting hose assembly... The heater core and water outlet hose assembly are both mounted on the heater core and water outlet hose assembly. The drive disc assembly and torsional damper assembly are coaxially fixed to the lower rear end of the engine body and connected to the output end of the engine body. The coolant inlet and outlet of the heater core and water outlet hose assembly, the small circulation connecting hose assembly and the heater core and water outlet hose assembly are interconnected and connected to the upstream of the inlet of the electronic main water pump assembly through the coolant flow pipeline. The heater core and water outlet hose assembly is connected to the outlet end of the EGR water outlet hose assembly.

[0013] The engine block is equipped with a large cooling loop. In this large cooling loop, the inlet of the vehicle radiator and the electronic main water pump assembly are connected through a coolant flow pipe. The outlet of the electronic main water pump assembly is connected to the water jacket inlet of the cylinder block assembly via an inlet hose assembly, an inlet pipe and O-ring assembly, and an inlet adapter assembly. The exhaust side of the cylinder block water jacket and the exhaust side water jacket of the cylinder head are vertically connected upwards. The exhaust side water jacket of the cylinder head and the intake side water jacket of the cylinder head are horizontally connected. The intake side water jacket of the cylinder head and the intake side water jacket of the cylinder block are vertically connected downwards. The intake side water jacket of the cylinder block is connected to the thermostat and cover assembly through a coolant flow pipe. The outlet of the thermostat and cover assembly is connected to the inlet of the vehicle radiator through a coolant flow pipe.

[0014] The engine body is equipped with two small cooling cycles: a small cooling cycle for the turbocharger and oil cooler, and a small cooling cycle for the EGR cooler. In the small cooling loop of the turbocharger and oil cooler, the inlet pipe and O-ring assembly are connected to the coolant inlet of the turbocharger assembly via the turbocharger inlet hose assembly and the turbocharger inlet / outlet steel pipe assembly. The inlet pipe and O-ring assembly are connected to the coolant inlet of the oil cooler assembly via the oil cooler inlet hose assembly. The coolant outlet of the turbocharger assembly is connected to the heater core inlet / outlet steel pipe assembly via the turbocharger outlet hose assembly. The coolant outlet of the oil cooler assembly is connected to the heater core inlet / outlet steel pipe assembly via the oil cooler outlet hose assembly. The heater core inlet / outlet steel pipe assembly is connected to the upstream of the inlet of the electronic main water pump assembly via a coolant flow pipe. In the small cooling cycle of the EGR cooler, the cylinder head exhaust manifold water jacket is connected to the coolant inlet of the low-pressure cooling EGR assembly through the cooling EGR inlet water pipe nozzle. The coolant outlet of the low-pressure cooling EGR assembly is connected to the heater core inlet and outlet water pipe assembly through the EGR outlet hose assembly. The heater core inlet and outlet water pipe assembly is connected to the upstream of the inlet of the electronic main water pump assembly through the coolant flow pipeline.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. The engine adopts a reverse-mounted layout with a 0°~10° tilt towards the exhaust side. The components are integrated into the front, exhaust side, intake side, rear and bottom layouts, resulting in a compact overall structure that can adapt to the compact engine compartment layout requirements of vehicles of the same displacement class, thus improving vehicle-engine compatibility.

[0016] 2. It adopts a low-pressure EGR structure with air intake after the turbocharger and before the three-way catalytic converter. The low-pressure cooled EGR assembly is located at the high point of the cylinder head exhaust side, and is cooled by the coolant intake point at the high point of the cylinder head exhaust side. This effectively avoids the problems of liquid accumulation and vapor lock in the EGR cooling system, ensures the stable operation of the EGR system under all operating conditions, reduces the engine combustion temperature, reduces pollutant emissions, and meets environmental protection requirements.

[0017] 3. The engine has a built-in TVD pulley assembly and is enclosed by a synchronizer chain cover assembly, which can effectively suppress crankshaft torsional vibration, reduce vibration and noise during engine operation, and improve the overall NVH performance.

[0018] 4. The cooling system is equipped with a large circulation loop and two independent small circulation loops, which can meet the core cooling needs of the cylinder block and cylinder head, while providing targeted cooling for the turbocharger, oil cooler, and low-pressure cooling EGR assembly. It is suitable for all operating conditions such as engine cold start and low load, and takes into account both the rapid warm-up of coolant and the cooling effect of key components.

[0019] 5. The lubrication system integrates a fully variable displacement oil pump, which, together with the oil cooler, filters, controls the temperature, and circulates the lubricating oil, providing stable lubrication and cooling for the moving parts inside the engine and the turbocharger bearings, ensuring the viscosity and lubrication performance of the lubricating oil, and extending the engine's service life.

[0020] 6. The integrated and compact layout design of the whole machine reduces the overall size and weight of the engine and increases the power density while ensuring the full realization of the functions of each system. At the same time, the rational layout of each system reduces energy consumption and realizes the energy-saving operation of the engine.

[0021] In summary, through reasonable layout design, system matching, and structural optimization, this invention effectively improves the engine's NVH performance while achieving compact engine bay adaptation. It also ensures stable operation of various systems such as EGR, cooling, and lubrication under all operating conditions, and achieves energy-saving and environmentally friendly operation of the engine, thus improving the overall performance of the range extender engine. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the front end of the present invention; Figure 2 This is a schematic diagram of the air intake side of the present invention; Figure 3 This is a schematic diagram of the exhaust side of the present invention. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0024] This embodiment describes a novel overall layout structure for a range-extending engine, including an engine body. The engine body is inverted and tilted towards the exhaust side at an angle of 0° to 10°. A cylinder head is sealed and fixed to the upper end of the cylinder block assembly 10 on the engine body. The water jacket of the cylinder block assembly 10 is connected to the water jacket of the cylinder head via a coolant flow pipe. A front-end assembly, an exhaust-side assembly, an intake-side assembly, a rear-end assembly, and a bottom assembly are respectively arranged at the front-end assembly, exhaust-side assembly, intake-side assembly, rear-end assembly, and bottom assembly. Coolant flow pipes, oil flow pipes, turbocharger flow pipes, and exhaust gas flow pipes are provided between the front-end assembly, exhaust-side assembly, intake-side assembly, rear-end assembly, and bottom assembly. The engine body integrates the cylinder head exhaust manifold water jacket. It is a low-pressure EGR structure with intake after the turbocharger and before the three-way catalytic converter. The intake end of the low-pressure cooling EGR assembly 32 of the exhaust side component is connected to the exhaust port of the turbocharger assembly 36 and the exhaust pipe upstream of the three-way catalytic converter. The exhaust end of the low-pressure cooling EGR assembly 32 is connected to the compressor intake end of the turbocharger assembly 36 through the exhaust gas flow pipe. The engine body has a built-in TVD wheel assembly, which is built into the inner cavity of the synchronizer chain cover assembly 28. A coolant intake point is provided at the high point of the exhaust side of the cylinder head. The coolant intake point is connected to the cylinder head water jacket and is connected to the coolant inlet of the low-pressure cooling EGR assembly 32 through the coolant flow pipe. The low-pressure cooling EGR assembly 32 is located at the high point of the exhaust side of the cylinder head.

[0025] The engine body is a fuel-supply type range extender engine with a rated displacement of 2.0L; a valve cover and oil filler cap assembly 31 is fixed above the cylinder head, and an ignition coil 23 is arranged on the valve cover and oil filler cap assembly 31; the front end assembly includes an oil dipstick guide 18, an oil dipstick 22, an electromagnetic coil 26, a synchronizer chain cover assembly 28, and an engine front mount 30. The engine front mount 30 and the synchronizer chain housing assembly 28 are both mounted on the front end of the engine body. The electromagnetic coil 26 is arranged on the upper part of the synchronizer chain housing assembly 28, the oil dipstick guide 18 is arranged on the lower part of the synchronizer chain housing assembly 28, and the oil dipstick 22 is slidably inserted into the oil dipstick guide 18.

[0026] The bottom assembly includes an oil pan assembly 14, an oil filter 13, and a fully variable displacement oil pump; The oil pan assembly 14 is sealed and fixed to the bottom of the cylinder block assembly 10. The oil filter 13 is fixed to the rear end of the oil pan assembly 14. The oil inlet of the fully variable displacement oil pump is connected to the oil outlet of the oil pan assembly 14 through an oil flow pipeline. The oil outlet of the fully variable displacement oil pump is connected to the oil inlet of the oil filter 13 through an oil flow pipeline. The oil outlet of the oil filter 13 is connected to the main oil passage inlet of the engine body through an oil flow pipeline. The main oil passage of the engine body is connected to the oil inlet of the oil cooler assembly 15 through an oil flow pipeline. The oil return end of the oil cooler assembly 15 is connected to the oil inlet of the oil pan assembly 14 through an oil flow pipeline.

[0027] The exhaust-side assembly includes an inlet pipe and O-ring assembly 6, an inlet adapter assembly 29, a low-pressure cooling EGR assembly 32, a turbocharger oil inlet pipe assembly 33, a turbocharger oil return pipe assembly 34, a turbocharger inlet hose assembly 35, a turbocharger assembly 36, a turbocharger inlet and outlet water steel pipe assembly 37, an EGR outlet hose assembly 38, and a turbocharger outlet hose assembly 39. The water inlet pipe and O-ring assembly 6, water inlet adapter assembly 29, low-pressure cooling EGR assembly 32, turbocharger oil inlet pipe assembly 33, turbocharger oil return pipe assembly 34, turbocharger water inlet hose assembly 35, turbocharger assembly 36, turbocharger water inlet and outlet steel pipe assembly 37, EGR water outlet hose assembly 38, and turbocharger water outlet hose assembly 39 are all mounted on the exhaust side of the engine block. The low-pressure cooling EGR assembly 32 is mounted at the high point of the cylinder head exhaust side, and the turbocharger assembly 36 is mounted in the middle of the engine block exhaust side. The water inlet adapter assembly 29 and the water inlet pipe and O-ring assembly 6 are arranged at the lower end of the engine block exhaust side. The exhaust manifold water jacket integrated with the cylinder head is provided with a cooling EGR water inlet connector, which is connected to the coolant inlet of the low-pressure cooling EGR assembly 32.

[0028] The oil outlet of the turbocharger inlet pipe assembly 33 and the oil inlet of the turbocharger return pipe assembly 34 are both connected to the turbocharger assembly 36. The turbocharger inlet and outlet water pipe assembly 37 are respectively connected to the coolant inlet and coolant outlet of the turbocharger assembly 36. The water outlet of the turbocharger inlet hose assembly 35 and the water inlet of the turbocharger outlet hose assembly 39 are both connected to the turbocharger inlet and outlet water pipe assembly 37. The water inlet of the EGR outlet hose assembly 38 is connected to the coolant outlet of the low-pressure cooling EGR assembly 32. The oil return end of the turbocharger return pipe assembly 34 is connected to the oil pan assembly 14 through an oil flow pipeline.

[0029] The intake-side assembly includes an inlet water hose assembly 7, an electronic main water pump assembly 9, an oil cooler assembly 15, an oil cooler outlet water hose assembly 16, an oil cooler inlet water hose assembly 17, an intake manifold assembly 19, a water-to-air intercooler assembly 20, an electronic throttle body 21, a turbocharger outlet pipe 24, an intake pressure relief valve 25, and a thermostat and housing assembly 27. The inlet hose assembly 7, electronic main water pump assembly 9, oil cooler assembly 15, oil cooler outlet hose assembly 16, oil cooler inlet hose assembly 17, intake manifold assembly 19, water-to-intercooler assembly 20, electronic throttle body 21, turbocharger outlet pipe 24, intake pressure relief valve 25, and thermostat and housing assembly 27 are all mounted on the intake side of the engine block. The coolant outlet of the thermostat and housing assembly 27 is connected to the inlet of the vehicle radiator via a coolant flow pipe. The intake end of the intake pressure relief valve 25 is connected to the turbocharger outlet... The air pipe 24 is connected to the intake manifold 25. The outlet end of the intake pressure relief valve 25 is connected to the intake front end of the turbocharger assembly 36. The inlet end of the turbocharger outlet pipe 24 is connected to the compressor outlet end of the turbocharger assembly 36. The outlet end of the turbocharger outlet pipe 24 is connected to the boost gas inlet end of the water-to-intercooler assembly 20. The boost gas outlet end of the water-to-intercooler assembly 20 is connected to the inlet end of the electronic throttle body 21. The outlet end of the electronic throttle body 21 is connected to the boost gas inlet end of the intake manifold assembly 19.

[0030] The inlet of the electronic main water pump assembly 9 is connected to the vehicle radiator, and the outlet of the electronic main water pump assembly 9 is connected to the inlet end of the inlet hose assembly 7. The outlet end of the inlet hose assembly 7 is connected to the inlet end of the inlet pipe and O-ring assembly 6. The outlet end of the inlet pipe and O-ring assembly 6 is connected to the inlet end of the inlet adapter assembly 29. The inlet pipe and O-ring assembly 6 is also connected to the inlet end of the turbocharger inlet hose assembly 35 and the inlet end of the oil cooler inlet hose assembly 17. The outlet end of the oil cooler inlet hose assembly 17 is connected to the coolant inlet end of the oil cooler assembly 15. The inlet end of the oil cooler outlet hose assembly 16 is connected to the coolant outlet end of the oil cooler assembly 15.

[0031] The rear-end components include a torsion pipe assembly 1, an intake mixing valve assembly 2, an oil-gas desorption pipe assembly 3, a heater inlet and outlet water steel pipe assembly 4, a small circulation connecting hose assembly 5, a heater outlet water hose assembly 8, a drive disc assembly 11, and a torsional damper assembly 12. The curved pipe assembly 1, the intake mixing valve assembly 2, and the oil-gas desorption pipe assembly 3 are assembled at the upper rear end of the engine body. The outlet end of the curved pipe assembly 1 is connected to the intake end of the intake mixing valve assembly 2, and the outlet end of the intake mixing valve assembly 2 is connected to the engine intake system. The intake end of the oil-gas desorption pipe assembly 3 is connected to the vehicle fuel system, and the outlet end of the oil-gas desorption pipe assembly 3 is connected to the engine intake system. The heater inlet and outlet water pipe assembly 4 is assembled at the middle rear end of the engine body. The small circulation connecting hose assembly 5 and... The heater core hose assembly 8 is mounted on the heater core inlet and outlet hose assembly 4. The drive disc assembly 11 and the torsional damper assembly 12 are coaxially fixed to the lower rear end of the engine body and connected to the output end of the engine body. The coolant inlet and outlet hose assembly 4, the small circulation connecting hose assembly 5 and the heater core hose assembly 8 are interconnected and connected to the upstream of the inlet of the electronic main water pump assembly 9 through the coolant flow pipeline. The heater core inlet and outlet hose assembly 4 is connected to the outlet end of the EGR outlet hose assembly 38.

[0032] The engine block is equipped with a large cooling loop. In this large cooling loop, the inlet of the vehicle radiator and the electronic main water pump assembly 9 are connected through a coolant flow pipe. The outlet of the electronic main water pump assembly 9 is connected to the water jacket inlet of the cylinder block assembly 10 via the water inlet hose assembly 7, the water inlet pipe and O-ring assembly 6, and the water inlet adapter assembly 29. The exhaust side of the cylinder block water jacket of the cylinder block assembly 10 is vertically connected to the exhaust side water jacket of the cylinder head. The exhaust side water jacket of the cylinder head is horizontally connected to the intake side water jacket of the cylinder head. The intake side water jacket of the cylinder head is vertically connected to the intake side water jacket of the cylinder block. The intake side water jacket of the cylinder block is connected to the thermostat and cover assembly 27 through a coolant flow pipe. The outlet of the thermostat and cover assembly 27 is connected to the inlet of the vehicle radiator through a coolant flow pipe.

[0033] The engine body is equipped with two small cooling cycles: a small cooling cycle for the turbocharger and oil cooler, and a small cooling cycle for the EGR cooler. In the small cooling loop of the turbocharger and oil cooler, the inlet pipe and O-ring assembly 6 are connected to the coolant inlet of the turbocharger assembly 36 via the turbocharger inlet hose assembly 35 and the turbocharger inlet / outlet steel pipe assembly 37. The inlet pipe and O-ring assembly 6 are connected to the coolant inlet of the oil cooler assembly 15 via the oil cooler inlet hose assembly 17. The coolant outlet of the turbocharger assembly 36 is connected to the heater core inlet / outlet steel pipe assembly 4 via the turbocharger outlet hose assembly 39. The coolant outlet of the oil cooler assembly 15 is connected to the heater core inlet / outlet steel pipe assembly 4 via the oil cooler outlet hose assembly 16. The heater core inlet / outlet steel pipe assembly 4 is connected to the upstream of the inlet of the electronic main water pump assembly 9 via a coolant flow pipe. In the small cooling cycle of the EGR cooler, the cylinder head exhaust manifold water jacket is connected to the coolant inlet of the low-pressure cooling EGR assembly 32 through the cooling EGR inlet water pipe nozzle. The coolant outlet of the low-pressure cooling EGR assembly 32 is connected to the heater inlet and outlet water pipe assembly 4 through the EGR outlet water hose assembly 38. The heater inlet and outlet water pipe assembly 4 is connected to the upstream of the inlet of the electronic main water pump assembly 9 through the coolant flow pipe.

[0034] When using this invention, the overall layout, which is reverse-mounted and tilted at 0°~10° towards the exhaust side based on the horizontal mounting surface of the engine, is adapted to the installation requirements of the compact engine compartment of the vehicle. The cylinder head is sealed and fixed at the upper end of the cylinder block assembly 10. The valve cover and oil filler cap assembly 31 is fixed above the cylinder head. The ignition coil 23 arranged on the valve cover and oil filler cap assembly 31 provides ignition energy for the combustible mixture in the cylinder. The front end of the engine is equipped with a synchronizer cover assembly 28 and an engine front mount 30. The synchronizer cover assembly 28 has an electromagnetic coil 26 arranged on the upper part and an oil dipstick guide 18 at the lower part. An oil dipstick 22 slides through the oil dipstick guide 18. The synchronizer chain housing assembly 28 encloses the TVD wheel assembly. A drive disc assembly 11 and a torsional damper assembly 12 are coaxially fixed to the lower rear end of the engine. The drive disc assembly 11 and the torsional damper assembly 12 are connected to the output end of the engine body at the rear end to transmit power and suppress torsional vibration at the output end. During engine operation, the fuel supply system provides the fuel required for combustion. Fresh air enters the engine through the intake system; specifically, the air is pressurized by the turbocharger assembly 36 and then enters the water-to-air intercooler assembly 20 through the turbocharger outlet pipe 24 for cooling. An intake pressure relief valve 25 is installed on the turbocharger outlet pipe 24. It can be activated when the boost pressure is too high, allowing excess boosted gas to flow back to the intake front of the turbocharger assembly 36, ensuring stable intake system pressure. The cooled boosted air then enters the cylinder through the electronic throttle body 21 and intake manifold assembly 19 to mix with fuel to form a combustible mixture. The exhaust gas after combustion first flows through the turbine end of the turbocharger assembly 36 to drive the turbine to do work. Part of the exhaust gas enters the three-way catalytic converter through the exhaust system and is then discharged. The other part enters the low-pressure cooled EGR assembly 32 in parallel through the intake structure after the turbine and before the three-way catalytic converter. After completing exhaust gas cooling and recirculation, it is sent to the compressor intake end of the turbocharger assembly 36. Mixing with fresh air lowers combustion temperature and reduces pollutant emissions. Meanwhile, the low-pressure cooling EGR assembly 32 is located at a high point on the exhaust side of the cylinder head. The coolant intake point at the high point on the exhaust side of the cylinder head draws water directly from the cylinder head water jacket to provide cooling medium for the low-pressure cooling EGR assembly 32, avoiding liquid accumulation and vapor lock problems in the EGR cooling system and ensuring stable operation of the EGR system under all operating conditions. During engine operation, blow-by gas in the crankcase enters the intake system through the crankcase assembly 1 and the intake mixing valve assembly 2. The fuel desorption pipe assembly 3 can send the fuel desorbed from the fuel system into the intake system to participate in combustion, avoiding emissions pollution caused by direct fuel exhaust. During engine operation, the electronic main water pump assembly 9 provides circulation power for the cooling system. Driven by the electronic main water pump assembly 9, the coolant flows through the inlet hose assembly 7, the inlet pipe and O-ring assembly 6, and the inlet adapter assembly 29 into the water jacket of the cylinder block assembly 10. It flows vertically upwards from the exhaust side of the cylinder block water jacket into the cylinder head exhaust side water jacket, preferentially cooling the high-temperature area on the exhaust side. Then, it flows laterally from the cylinder head exhaust side to the cylinder head intake side water jacket, achieving uniform cooling of the entire cylinder head. Finally, it flows vertically downwards into the cylinder block intake side water jacket. The coolant flows back to the vehicle radiator via the thermostat and housing assembly 27 to complete heat dissipation, forming a large cooling loop. Simultaneously, two coolant branches branch off from the inlet pipe and O-ring assembly 6. One branch flows through the turbocharger inlet hose assembly 35 and the turbocharger inlet / outlet hose assembly 37 to the turbocharger assembly 36; the other branch flows through the oil cooler inlet hose assembly 17 to the oil cooler assembly 15. After cooling their respective components, the coolant from both branches converges through the turbocharger outlet hose assembly 39 and the oil cooler outlet hose assembly 16, respectively. The heater core and outlet water hose assembly 4 is equipped with a small circulation connecting hose assembly 5 and a heater outlet water hose assembly 8. The coolant inlets and outlets of the heater core and outlet water hose assembly 4, the small circulation connecting hose assembly 5, and the heater outlet water hose assembly 8 are interconnected. Ultimately, the coolant flows back through the heater core and outlet water hose assembly 4 to the upstream of the inlet of the electronic main water pump assembly 9, forming a small cooling loop for the turbocharger and oil cooler. In addition, the coolant at the cylinder head integrated exhaust manifold water jacket is cooled via the EGR inlet water connection. After the nozzle enters the low-pressure cooling EGR assembly 32 and completes cooling, it flows through the EGR outlet hose assembly 38 into the heater inlet and outlet water steel pipe assembly 4, and then flows back to the upstream of the inlet of the electronic main water pump assembly 9, forming a small cooling loop for the EGR cooler. The dual cooling loop design can quickly increase the coolant temperature under engine cold start and low load conditions, while ensuring the independent cooling needs of the turbocharger assembly 36, oil cooler assembly 15, and low-pressure cooling EGR assembly 32, thus improving the engine's adaptability to all operating conditions. During engine operation, the lubricating oil in the oil pan assembly 14 is driven by the fully variable displacement oil pump and enters the oil filter 13 to filter impurities. The oil filter 13 is fixed at the rear end of the oil pan assembly 14. The filtered clean lubricating oil enters the engine's main oil passage. One path provides lubrication and cooling for internal moving parts such as the crankshaft connecting rod mechanism and valve train. The other path enters the turbocharger assembly 36 through the turbocharger inlet pipe assembly 33, providing lubrication and cooling for the turbocharger bearings. After that, it flows back to the oil pan assembly 14 through the turbocharger return pipe assembly 34. At the same time, the lubricating oil in the main oil passage also enters the oil cooler assembly 15 for further processing. After temperature control adjustment, the lubricating oil flows back to the oil pan assembly 14, ensuring the viscosity and stable lubrication performance of the lubricating oil. During engine operation, the TVD wheel assembly built into the synchronous chain cover assembly 28 can effectively suppress crankshaft torsional vibration, significantly reduce vibration and noise during engine operation, and improve the overall NVH performance. At the same time, the front-end components, exhaust-side components, intake-side components, rear-end components, and bottom components of the engine are integrated in a specific orientation, which can significantly reduce the overall size and weight of the engine, increase power density, adapt to the layout requirements of various compact engine compartments, and achieve energy-saving, environmentally friendly, and low-vibration stable operation of the range extender engine.

[0035] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A novel overall layout structure for a range-extending engine, characterized in that: The engine body includes an engine block; the engine block is inverted and tilted towards the exhaust side at an angle of 0°~10°. The cylinder head is sealed and fixed at the upper end of the cylinder block assembly (10) on the engine block. The water jacket of the cylinder block assembly (10) is connected to the water jacket of the cylinder head through a coolant flow pipe. The front end, exhaust side, intake side, rear end, and bottom of the engine block are respectively provided with a front end assembly, an exhaust side assembly, an intake side assembly, a rear end assembly, and a bottom assembly. A coolant flow pipe, an oil flow pipe, a boost gas flow pipe, and an exhaust gas flow pipe are provided between the front end assembly, the exhaust side assembly, the intake side assembly, the rear end assembly, and the bottom assembly. The engine block integrates the cylinder head exhaust manifold water jacket and is a low-pressure intake type with air taken from the rear of the turbocharger and the front of the three-way catalytic converter. The EGR structure is such that the intake end of the low-pressure cooling EGR assembly (32) of the exhaust side component is connected to the turbine end outlet of the turbocharger assembly (36) and the exhaust gas pipeline upstream of the three-way catalytic converter. The outlet end of the low-pressure cooling EGR assembly (32) is connected to the compressor intake end of the turbocharger assembly (36) through the exhaust gas flow pipeline. The engine body has a built-in TVD wheel assembly, which is built into the inner cavity of the synchronizer chain cover assembly (28). A coolant water intake point is provided at the high point of the exhaust side of the cylinder head. The coolant water intake point is connected to the cylinder head water jacket and is connected to the coolant water inlet of the low-pressure cooling EGR assembly (32) through the coolant flow pipeline. The low-pressure cooling EGR assembly (32) is located at the high point of the exhaust side of the cylinder head.

2. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The engine body is a fuel-supply type range extender engine. A valve cover and oil filler cap assembly (31) is fixed on the cylinder head. An ignition coil (23) is arranged on the valve cover and oil filler cap assembly (31). The front end assembly includes an oil dipstick guide (18), an oil dipstick (22), an electromagnetic coil (26), a synchronizing chain cover assembly (28), and an engine front mount (30). The engine front mount (30) and the synchronizing chain cover assembly (28) are both mounted on the front end of the engine body. The electromagnetic coil (26) is arranged on the upper part of the synchronizing chain cover assembly (28). The oil dipstick guide (18) is arranged on the lower part of the synchronizing chain cover assembly (28). The oil dipstick (22) is slidably inserted into the oil dipstick guide (18).

3. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The bottom assembly includes an oil pan assembly (14), an oil filter (13), and a fully variable displacement oil pump; The oil pan assembly (14) is sealed and fixed at the bottom of the cylinder block assembly (10). The oil filter (13) is fixed at the rear end of the oil pan assembly (14). The oil inlet of the fully variable displacement oil pump is connected to the oil outlet of the oil pan assembly (14) through an oil flow pipeline. The oil outlet of the fully variable displacement oil pump is connected to the oil inlet of the oil filter (13) through an oil flow pipeline. The oil outlet of the oil filter (13) is connected to the main oil passage inlet of the engine body through an oil flow pipeline. The main oil passage of the engine body is connected to the oil inlet of the oil cooler assembly (15) through an oil flow pipeline. The oil return end of the oil cooler assembly (15) is connected to the oil inlet of the oil pan assembly (14) through an oil flow pipeline.

4. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The exhaust-side assembly includes an inlet pipe and O-ring assembly (6), an inlet adapter assembly (29), a low-pressure cooling EGR assembly (32), a turbocharger oil inlet pipe assembly (33), a turbocharger oil return pipe assembly (34), a turbocharger water inlet hose assembly (35), a turbocharger assembly (36), a turbocharger inlet and outlet water steel pipe assembly (37), an EGR water outlet hose assembly (38), and a turbocharger water outlet hose assembly (39). The inlet pipe and O-ring assembly (6), the inlet adapter assembly (29), the low-pressure cooling EGR assembly (32), the turbocharger oil inlet pipe assembly (33), the turbocharger oil return pipe assembly (34), the turbocharger water inlet hose assembly (35), the turbocharger assembly (36), the turbocharger inlet and outlet water steel pipe assembly (37), the EGR water outlet hose assembly (38), and the turbocharger water outlet hose assembly (39) are all assembled on the exhaust side of the engine body. The low-pressure cooling EGR assembly (32) is mounted at the high point of the cylinder head exhaust side. The turbocharger assembly (36) is mounted in the middle of the engine body exhaust side. The lower end of the engine body exhaust side is provided with a water inlet adapter assembly (29) and a water inlet pipe and O-ring assembly (6). The exhaust manifold water jacket integrated in the cylinder head is provided with a cooling EGR water inlet pipe nozzle. The cooling EGR water inlet pipe nozzle is connected to the coolant inlet of the low-pressure cooling EGR assembly (32).

5. The novel range-extending engine overall layout structure according to claim 4, characterized in that: The oil outlet of the turbocharger inlet pipe assembly (33) and the oil inlet of the turbocharger return pipe assembly (34) are both connected to the turbocharger assembly (36). The turbocharger inlet and outlet water pipe assembly (37) is connected to the coolant inlet and coolant outlet of the turbocharger assembly (36) respectively. The water outlet of the turbocharger inlet hose assembly (35) and the water inlet of the turbocharger outlet hose assembly (39) are both connected to the turbocharger inlet and outlet water pipe assembly (37). The water inlet of the EGR outlet hose assembly (38) is connected to the coolant outlet of the low-pressure cooling EGR assembly (32). The oil return end of the turbocharger return pipe assembly (34) is connected to the oil pan assembly (14) through the oil flow pipeline.

6. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The intake side assembly includes an intake hose assembly (7), an electronic main water pump assembly (9), an oil cooler assembly (15), an oil cooler outlet hose assembly (16), an oil cooler inlet hose assembly (17), an intake manifold assembly (19), a water-air intercooler assembly (20), an electronic throttle body (21), a turbocharger outlet pipe (24), an intake pressure relief valve (25), and a thermostat and housing assembly (27). The inlet hose assembly (7), electronic main water pump assembly (9), oil cooler assembly (15), oil cooler outlet hose assembly (16), oil cooler inlet hose assembly (17), intake manifold assembly (19), water-to-air intercooler assembly (20), electronic throttle body (21), turbocharger outlet pipe (24), intake pressure relief valve (25), and thermostat and housing assembly (27) are all mounted on the intake side of the engine body. The coolant outlet of the thermostat and housing assembly (27) is connected to the inlet of the vehicle radiator through a coolant flow pipe. The intake end of the intake pressure relief valve (25) is connected to the turbocharger. The pipeline of the exhaust pipe (24) is connected, the exhaust end of the intake pressure relief valve (25) is connected to the intake front end pipeline of the turbocharger assembly (36), the intake end of the turbocharger exhaust pipe (24) is connected to the compressor exhaust end of the turbocharger assembly (36), the exhaust end of the turbocharger exhaust pipe (24) is connected to the boost gas intake end of the water-air intercooler assembly (20), the boost gas exhaust end of the water-air intercooler assembly (20) is connected to the intake end of the electronic throttle body (21), and the exhaust end of the electronic throttle body (21) is connected to the boost gas intake end of the intake manifold assembly (19).

7. The novel range-extending engine overall layout structure according to claim 6, characterized in that: The inlet of the electronic main water pump assembly (9) is connected to the vehicle radiator, and the outlet of the electronic main water pump assembly (9) is connected to the inlet end of the inlet hose assembly (7). The outlet end of the inlet hose assembly (7) is connected to the inlet end of the inlet pipe and O-ring assembly (6), and the outlet end of the inlet pipe and O-ring assembly (6) is connected to the inlet end of the inlet adapter assembly (29). The pipe and O-ring assembly (6) is also connected to the inlet end of the turbocharger inlet hose assembly (35) and the inlet end of the oil cooler inlet hose assembly (17). The outlet end of the oil cooler inlet hose assembly (17) is connected to the coolant inlet end of the oil cooler assembly (15). The inlet end of the oil cooler outlet hose assembly (16) is connected to the coolant outlet end of the oil cooler assembly (15).

8. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The rear-end components include a torsion pipe assembly (1), an intake mixing valve assembly (2), an oil-gas desorption pipe assembly (3), a heater inlet and outlet water steel pipe assembly (4), a small circulation connecting hose assembly (5), a heater outlet water hose assembly (8), a drive disc assembly (11), and a torsional damper assembly (12). The curved pipe assembly (1), the intake mixing valve assembly (2), and the oil-gas desorption pipe assembly (3) are assembled at the upper rear end of the engine body. The outlet end of the curved pipe assembly (1) is connected to the intake end of the intake mixing valve assembly (2), and the outlet end of the intake mixing valve assembly (2) is connected to the engine intake system. The intake end of the oil-gas desorption pipe assembly (3) is connected to the vehicle fuel system, and the outlet end of the oil-gas desorption pipe assembly (3) is connected to the engine intake system. The heater inlet and outlet water pipe assembly (4) is assembled at the middle rear end of the engine body. The small circulation connecting hose assembly (5) and The heater water outlet hose assembly (8) is mounted on the heater water inlet and outlet steel pipe assembly (4). The drive disc assembly (11) and the torsional damper assembly (12) are coaxially fixed to the lower rear end of the engine body and connected to the output end of the engine body. The coolant inlet and outlet of the heater water inlet and outlet steel pipe assembly (4), the small circulation connecting hose assembly (5) and the heater water outlet hose assembly (8) are interconnected and connected to the upstream of the water inlet of the electronic main water pump assembly (9) through the coolant flow pipeline. The heater water inlet and outlet steel pipe assembly (4) is connected to the water outlet of the EGR water outlet hose assembly (38).

9. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The engine body is provided with a large cooling circulation. In the large cooling circulation, the inlet of the vehicle radiator and the electronic main water pump assembly (9) are connected through the coolant circulation pipeline. The outlet of the electronic main water pump assembly (9) is connected to the water jacket inlet of the cylinder block assembly (10) in sequence through the water inlet hose assembly (7), the water inlet pipe and O-ring assembly (6), and the water inlet adapter assembly (29). The cylinder block water jacket exhaust side of the cylinder block assembly (10) is vertically connected to the cylinder head exhaust side water jacket. The cylinder head exhaust side water jacket is horizontally connected to the cylinder head intake side water jacket. The cylinder head intake side water jacket is vertically connected to the cylinder block intake side water jacket. The cylinder block intake side water jacket is connected to the thermostat and cover assembly (27) through the coolant circulation pipeline. The outlet of the thermostat and cover assembly (27) is connected to the inlet of the vehicle radiator through the coolant circulation pipeline.

10. The novel range-extending engine overall layout structure according to claim 1, characterized in that: The engine body is equipped with two small cooling cycles: a small cooling cycle for the turbocharger and oil cooler, and a small cooling cycle for the EGR cooler. In the small cooling loop of the turbocharger and oil cooler, the inlet pipe and O-ring assembly (6) are connected to the coolant inlet of the turbocharger assembly (36) via the turbocharger inlet hose assembly (35) and the turbocharger inlet / outlet steel pipe assembly (37). The inlet pipe and O-ring assembly (6) are connected to the coolant inlet of the oil cooler assembly (15) via the oil cooler inlet hose assembly (17). The coolant outlet of the compressor assembly (36) is connected to the heater inlet and outlet water pipe assembly (4) via the turbocharger outlet hose assembly (39). The coolant outlet of the oil cooler assembly (15) is connected to the heater inlet and outlet water pipe assembly (4) via the oil cooler outlet hose assembly (16). The heater inlet and outlet water pipe assembly (4) is connected to the upstream of the inlet of the electronic main water pump assembly (9) via a coolant flow pipe. In the small cooling cycle of the EGR cooler, the cylinder head exhaust manifold water jacket is connected to the coolant inlet of the low-pressure cooling EGR assembly (32) through the cooling EGR inlet water pipe nozzle. The coolant outlet of the low-pressure cooling EGR assembly (32) is connected to the heater inlet and outlet water pipe assembly (4) through the EGR outlet hose assembly (38). The heater inlet and outlet water pipe assembly (4) is connected to the upstream of the water inlet of the electronic main water pump assembly (9) through the coolant flow pipeline.

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