A range extender system and vehicle

Abstract

This application provides a range extender system and a vehicle. The range extender system includes an engine structure, a motor structure, a first seal, and a second seal. The engine structure includes a cylinder block and a crankshaft. One end of the cylinder block has a connecting end plate. The crankshaft is disposed within the cylinder block and extends beyond the connecting end plate, with a gap between the crankshaft and the connecting end plate. The motor structure includes a housing connected to the connecting end plate and enclosing a motor cavity. The crankshaft extends into the motor cavity. The first seal and the second seal are respectively located within the gap and connected between the crankshaft and the connecting end plate, with a balance chamber between the first seal and the second seal. The connecting end plate has a vent, which communicates with the balance chamber and the motor cavity, and the motor cavity communicates with the outside. The balance chamber connects to atmospheric pressure to balance the air pressure within the engine or motor, reducing the risk of fluid crosstalk between the engine and motor, and maintaining good lubrication and cooling for the motor.

Description

Technical Field

[0001] This application belongs to the field of vehicle technology, specifically relating to a range extender system and a vehicle. Background Technology

[0002] With the development of technology and the improvement of living standards, people have put forward higher and higher requirements for vehicles. Among them, vehicles using range extender systems have been used more and more widely.

[0003] In the prior art, a range extender system typically includes an engine structure, a motor structure, and seals. The engine structure contains engine oil, the motor structure contains lubricating coolant, and the seals are located between the engine structure and the motor structure to seal the engine oil in the engine structure and the lubricating coolant in the motor structure.

[0004] However, during vehicle operation, there may be an imbalance in air pressure between the engine structure and the motor structure, causing the engine oil in the engine structure and the lubricating coolant in the motor structure to mix, contaminating the lubricating coolant and affecting the lubrication and cooling performance of the motor structure. Summary of the Invention

[0005] In view of the above problems, the present invention is proposed to provide a range extender system and vehicle that overcomes or at least partially solves the above problems.

[0006] To solve the above-mentioned technical problems, this application is implemented as follows: In a first aspect, embodiments of this application propose a range extender system, the range extender system comprising: an engine structure, an electric motor structure, a first seal, and a second seal; The engine structure includes a cylinder block and a crankshaft. One end of the cylinder block is provided with a connecting end plate. The crankshaft is disposed in the cylinder block and extends out of the connecting end plate. A gap is provided between the crankshaft and the connecting end plate. The motor structure includes a housing, which is connected to the connecting end plate and encloses to form a motor cavity, and the crankshaft extends into the motor cavity; The first seal and the second seal are respectively located within the gap and connected between the crankshaft and the connecting end plate, and a balance cavity is provided between the first seal and the second seal; The connecting end plate is provided with a ventilation channel, which is connected to the balance chamber and the motor cavity, and the motor cavity is connected to the outside.

[0007] Optionally, the connecting end plate is provided with a vent portion protruding toward the motor cavity, and the vent passage is disposed within the vent portion; The ventilation channel includes a connecting part and a liquid-blocking and air-permeable part that are interconnected. The connecting part is connected to the balance chamber, and the liquid-blocking and air-permeable part is connected to the motor cavity.

[0008] Optionally, the liquid-blocking and air-permeable part includes at least one bent air guide plate; And / or, the connecting portion extends radially, and the liquid-blocking and air-permeable portion extends axially from one end opposite to the connecting portion.

[0009] Optionally, a vent valve is provided on the top of the housing, the vent valve is located near the connecting end plate, and the motor cavity is connected to the outside through the vent valve.

[0010] Optionally, the range extender system further includes a return fluid channel, which is located at the bottom of the motor cavity and communicates with the balance chamber and the motor cavity.

[0011] Optionally, the motor structure includes a rotor shaft, which is disposed at the center of the motor cavity and divides the motor cavity into a first cavity and a second cavity, wherein the first cavity is located above the second cavity; The vent is connected to the first cavity, and the return fluid channel is connected to the second cavity.

[0012] Optionally, the bottom of the connecting end plate is provided with a protruding return liquid section, the range extender system includes a return liquid pipe, the return liquid pipe is disposed in the return liquid section, and the inner wall of the return liquid pipe forms the return liquid channel; Alternatively, the return channel may be located within the return section.

[0013] Optionally, the range extender system further includes a one-way valve connected to the side of the return channel away from the cavity.

[0014] Optionally, the return channel is inclined.

[0015] Secondly, embodiments of this application provide a vehicle that includes the aforementioned range extender system.

[0016] In this embodiment, the range extender system includes: an engine structure, a motor structure, a first seal, and a second seal; the engine structure includes a cylinder block and a crankshaft, one end of the cylinder block is provided with a connecting end plate, the crankshaft is disposed in the cylinder block and extends out of the connecting end plate, and a gap is provided between the crankshaft and the connecting end plate; the motor structure includes a housing, the housing is connected to the connecting end plate and surrounds to form a motor cavity, and the crankshaft extends into the motor cavity; the first seal and the second seal are respectively located in the gap and connected between the crankshaft and the connecting end plate, and a balance cavity is provided between the first seal and the second seal; a vent is provided in the connecting end plate, the vent communicates with the balance cavity, and the vent communicates with the motor cavity, and the motor cavity communicates with the outside. The first seal and the second seal are respectively connected between the crankshaft and the connecting end plate. That is, the first seal and the second seal can be coaxially spaced along the crankshaft axis. In this way, the spaced first seal and the second seal form a balance chamber. The balance chamber achieves pressure balance with the external atmospheric pressure through the air passage and the motor cavity. Therefore, when there is an air pressure imbalance between the engine structure and the motor structure, the atmospheric pressure connected by the balance chamber balances the air pressure in the engine structure or the motor structure. This greatly reduces the risk of cross-contamination between the engine oil and the lubricating coolant in the motor structure. It also reduces the risk of the engine oil and the lubricating coolant mixing, which may affect the lubricating coolant and cause its temperature to rise or its lubrication performance to decrease. This ensures that the lubricating coolant maintains good lubrication and cooling performance for the motor structure.

[0017] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.

[0018] The vehicle described in this application has the same or similar advantages as the prior art and the aforementioned range extender system, which will not be elaborated here. Attached Figure Description

[0019] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the structure of a range extender system according to an embodiment of this application; Figure 2 This is a schematic diagram of the ventilation section of a range extender system according to an embodiment of this application; Figure 3 This is a schematic diagram of the liquid return section of a range extender system according to an embodiment of this application.

[0020] Reference numerals: 11-Cylinder block; 12-Crankshaft; 13-Connecting end plate; 21-Housing shell; 22-Motor cavity; 30-First seal; 40-Second seal; 31-Balance chamber; 131-Ventilation passage; 132-Ventilation section; 321-Connecting section; 322-Liquid-blocking and ventilating section; 323-Bent air guide plate; 23-Ventilation valve; 133-Return passage; 24-Rotor shaft; 221-First cavity; 222-Second cavity; 134-Return section; 25-One-way valve; 26-Stator; 27-Rotor; 28-Support spokes. Detailed Implementation

[0021] Embodiments of the present invention will now be described in detail. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention. All other embodiments obtained by those skilled in the art based on the embodiments in this application without inventive effort are within the scope of protection of this application.

[0022] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0023] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0024] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0025] Reference Figures 1 to 3 This document illustrates a schematic diagram of a range extender system according to an embodiment of this application. The range extender system specifically includes: an engine structure, a motor structure, a first seal 30, and a second seal 40. The engine structure includes a cylinder block 11 and a crankshaft 12. One end of the cylinder block 11 is provided with a connecting end plate 13. The crankshaft 12 is disposed within the cylinder block 11 and extends beyond the connecting end plate 13, with a gap between the crankshaft 12 and the connecting end plate 13. The motor structure includes a housing 21, which is connected to the connecting end plate 13 and encloses to form a motor cavity 22. The crankshaft 12 extends into the motor cavity 22. The first seal 30 and the second seal 40 are respectively located within the gap and connected between the crankshaft 12 and the connecting end plate 13. A balance chamber 31 is provided between the first seal 30 and the second seal 40. A vent 131 is provided within the connecting end plate 13, communicating with the balance chamber 31 and the motor cavity 22, which is connected to the outside.

[0026] In this embodiment, the crankshaft 12 can be located at the center of the cylinder block 11. The first seal 30 and the second seal 40 are respectively located within the gap and connected between the crankshaft 12 and the connecting end plate 13. That is, the first seal 30 and the second seal 40 can be coaxially spaced along the axial direction of the crankshaft 12. In this way, the spaced first seal 30 and the second seal 40 form a balance chamber 31, which achieves pressure balance with the external atmospheric pressure through the air passage 131 and the motor cavity 22. Thus, when there is an air pressure imbalance between the engine structure and the motor structure, the atmospheric pressure connected by the balance chamber 31 balances the air pressure in the engine structure or the motor structure, which greatly reduces the risk of mutual mixing between the engine oil in the engine structure and the lubricating coolant in the motor structure. It also reduces the risk of the engine oil in the engine structure and the lubricating coolant in the motor structure mixing, which may affect the lubricating coolant and cause its temperature to rise or its lubrication performance to decrease. This ensures that the lubricating coolant maintains good lubrication and cooling performance for the motor structure.

[0027] Specifically, in this embodiment, a gap is provided between the connecting end plate 13 and the crankshaft 12. The first seal 30 and the second seal 40 are spaced apart within the gap. The balance cavity 31 between the first seal 30 and the second seal 40 is also located within the gap. The gap between the connecting end plate 13 and the crankshaft 12 provides a stable installation space for the first seal 30 and the second seal 40. For example, the boss of the connecting end plate 13 has a through hole along the axial direction. The crankshaft 12 passes through the through hole. The first seal 30 can be interference-fitted with the outer wall of the crankshaft 12 and the inner wall of the opening of the connecting end plate 13, and the second seal 40 can also be interference-fitted with the outer wall of the crankshaft 12 and the inner wall of the opening of the connecting end plate 13, so that the first seal 30 and the second seal 40 have good installation stability.

[0028] For example, in this embodiment, two spaced mounting grooves can be provided on the outer wall of the crankshaft 12, and the first seal 30 and the second seal 40 can be respectively embedded in the two mounting grooves, which facilitates the positioning and installation of the first seal 30 and the second seal 40 and improves the ease of assembly. In addition, grooves corresponding to the aforementioned mounting grooves can be provided on the hole wall of the opening of the connecting end plate 13, which further enhances the installation stability and reliability of the first seal 30 and the second seal 40. In this embodiment, the specific assembly method of the first seal 30 with the crankshaft 12 and the connecting end plate 13 is not limited and can be set according to actual needs.

[0029] In this embodiment, for example, the first seal 30 can be an annular structure including a first sealing lip, and the second seal 40 can also be an annular structure including a second sealing lip. During assembly, the first seal 30 can be first fitted onto the crankshaft 12, such that the first sealing lip faces the engine structure, i.e. Figure 1 The left-hand direction provides a good sealing effect for the engine structure. Then, the second seal 40 is installed on the crankshaft 12 at a distance from the first seal 30, so that the second sealing lip faces the motor structure, i.e. Figure 1 The direction on the right side provides a good sealing effect for the motor structure. For example, the first seal 30 can be silicone or rubber, and the second seal 40 can also be silicone or rubber. In this application embodiment, the specific types of the first seal 30 and the second seal 40 are not limited.

[0030] Specifically, in this embodiment, the motor structure may further include a stator 26 and a rotor 27, as well as a rotor support composed of a rotor shaft 24 and a support spoke 28. The stator 26, rotor 27, and rotor support composed of the rotor shaft 24 and the support spoke 28 are all disposed within the motor cavity 22. The stator 26 is disposed on the inner wall of the housing 21, the rotor 27 is disposed on the inner side of the stator 26, and the rotor support is connected to the inner side of the rotor 27. One end of the crankshaft 12 is provided with a flange that extends into the motor cavity 22. The rotor shaft 24 is connected to the flange structure and fixed by fasteners such as bolts, realizing a direct connection between the engine structure and the motor structure. This reduces the overall axial dimension of the range extender structure, thereby reducing the space it requires and facilitating the overall vehicle space layout.

[0031] Optionally, in this embodiment, the connecting end plate 13 is provided with a venting portion 132 protruding toward the motor cavity 22, and a venting channel 131 is disposed within the venting portion 132. The venting channel 131 includes a connecting portion 321 and a liquid-blocking and venting portion 322 that are interconnected. The connecting portion 321 is connected to the balance chamber 31, and the liquid-blocking and venting portion 322 is connected to the motor cavity 22. In this way, by providing a venting portion 132 protruding toward the motor cavity 22 on the connecting end plate 13, and by integrating the venting channel 131 onto the connecting end plate 13 to form the venting portion 132 integrally, compared to processing the venting channel 131 on another separate structure, the additional axial and radial space required is reduced. Moreover, the protruding structure can be located within the motor cavity 22. Thus, this application achieves an embedded layout of the venting channel 131 structure without increasing the overall axial dimension, thereby making the overall structure of the range extender compact and having a high degree of integration. Furthermore, the vent 131 is configured as a connecting portion 321 directly connected to the balance chamber 31 and a liquid-blocking and ventilating portion 322 connected to the motor cavity 22, thereby achieving functional segmentation of the gas flow path. Specifically, the connecting portion 321 can be used to provide low-resistance connectivity between the balance chamber 31 and the vent 131, and its flow resistance can be reduced by designing its cross-sectional shape and inner wall roughness. For example, the connecting portion 321 connects the balance chamber 31 and the vent 131, and its cross-section can be streamlined with a smooth inner wall, reducing the flow resistance between the balance chamber 31 and the vent 131 compared to a conventional straight-hole channel. The liquid-blocking and ventilating portion 322 serves the dual function of both ventilation and liquid blocking, and can intercept oil droplets or oil mist migrating with the airflow by utilizing inertial separation effect through shape design, reduced diameter section, or baffle structure. For example, when an oil-gas mixture is generated in the balance chamber 31 due to temperature fluctuations, the connecting part 321 allows the gas to quickly enter the ventilation channel 131, while the liquid-blocking and air-permeable part 322, under the blocking effect of the internal bending air guide plate 323, allows the oil droplets to break away from the airflow due to centrifugal force and return to the balance chamber 31 or the motor oil pool, thereby realizing the recycling and reuse of the oil.

[0032] In some embodiments of this application, the vent 132 may be located in the upper region of the crankshaft 12, thereby allowing the protruding vent 132 to trap oil and reduce the risk of leakage into the motor housing 22. For example, if oil accumulates in the balance chamber 31, since the inlet of the vent 132 is higher than the top of the balance chamber 31, the oil must overcome gravity to climb into the vent 131, while gas, due to its low density, can pass through easily. Furthermore, the structural design of the liquid-blocking vent 322 (such as an upwardly extending channel) can further increase the path resistance for liquid medium migration.

[0033] In the embodiments of this application, for example, the cross-sectional shape of the connecting part 321 can be circular, elliptical, or rectangular, and can be set according to actual needs. The cross-sectional shape of the connecting part 321 is not limited in the embodiments of this application.

[0034] Optionally, in this embodiment, the liquid-blocking and ventilating part 322 includes at least one bent air guide plate 323; and / or, the connecting part 321 extends radially, and the end of the liquid-blocking and ventilating part 322 opposite to the connecting part 321 extends axially. Thus, the liquid-blocking and ventilating part 322 can achieve the dual functions of air permeability and liquid blocking through at least one bent air guide plate 323, utilizing the inertial separation effect to intercept oil droplets or oil mist migrating with the airflow. Specifically, the density of engine oil droplets is approximately 800 times that of air. When the low-pressure gas in the balance chamber 31 enters the bent air guide plate 323, the low-pressure gas flow can smoothly change direction along the bend of the air passage, while larger-diameter liquid oil droplets, due to greater inertia, will impact the air passage wall at the bend, adhere and coalesce, and flow back to the bottom of the balance chamber 31 along the wall, ultimately flowing back to the oil sump at the bottom of the generator structure, preventing liquid oil from entering the motor cavity 22 with the airflow.

[0035] Furthermore, the connecting portion 321 extends radially, allowing the gaseous light components in the balance chamber 31 to rise and be transported to the top of the motor cavity 22, while the liquid oil, due to its higher density, sinks and is transported to the oil sump at the bottom of the generator structure. Compared to a directly horizontally positioned connecting portion 321, where liquid oil might directly enter the vent 131 due to vibration or pressure fluctuations, causing cross-contamination between the engine oil and the lubricating coolant in the motor structure and compromising the purity of both media, this design further reduces the risk of engine oil mixing with the motor coolant and reducing its insulation or heat dissipation efficiency. Moreover, the horizontally extending end of the liquid-blocking venting portion 322 facilitates the separation of oil mist within the gas and its passage to the upper part of the motor cavity 22, thereby enabling the balance chamber 31 to achieve pressure balance with the external atmospheric pressure more quickly through the motor cavity 22.

[0036] For example, in the embodiments of this application, at least one bent air guide plate 323 can be formed by integral casting or machining, such as Figure 2 As shown, the bent air guide plate 323 can be a 90° right-angle structure. Figure 2 The diagram shows a bent air guide plate 323 with four 90° right-angle structures. Furthermore, the number of 90° right-angle structures in the bent air guide plate 323 can also be one, two, three, or five, forming a labyrinth-structured liquid-blocking and air-permeable portion 322. Additionally, the bent air guide plate 323 can also be an arc-shaped structure or a spiral structure. The specific type and number of bent air guide plates 323 are not limited in this embodiment.

[0037] Optionally, in this embodiment, a vent valve 23 is provided at the top of the housing 21, and the vent valve 23 is located near the connecting end plate 13. The motor cavity 22 communicates with the outside through the vent valve 23. Since low-density gas will be transported upwards, a vent valve 23 is provided at the top of the housing 21. For example, an opening can be provided at the top of the housing 21 near the connecting end plate 13, and the vent valve 23 is embedded in the opening, so that the airflow has a shorter transmission path and improves the balancing efficiency. Furthermore, the vent valve 23 enables controllable ventilation and protection between the motor cavity 22 and the outside, preventing leakage and backflow, so that the motor cavity 22 has good sealing performance, avoiding oil splatter formed by oil cooling at high speeds of the motor structure being carried out of the housing 21 by the airflow and causing oil stains, and preventing external liquids from flowing back into the motor cavity 22 in water immersion or high-pressure water washing scenarios.

[0038] In this embodiment, for example, a sealing ring may be provided between the vent valve 23 and the opening at the top of the housing 21 to seal the vent valve 23 and the opening. For example, there may be one, two, or three sealing rings, which can be set according to the actual needs based on the size of the vent valve 23 and the opening. This embodiment does not limit the specific number of sealing rings. For example, the sealing ring may also be an integral structure with the vent valve 23. This embodiment also does not limit the specific arrangement of the sealing rings.

[0039] For example, in this embodiment, the opening threshold of the vent valve 23 can be set to ±1-3 kPa, which is 1 / 5-1 / 3 of the rated pressure of the oil seal (e.g., 8-10 kPa). This ensures dynamic balance within the motor cavity 22 under normal temperature cycling and transient pressure fluctuations, and maintains a good sealing state for the motor cavity 22 when statically stationary, preventing humid air or dust from slowly seeping into the motor cavity 22 over a long period, leading to lubricating oil emulsification and bearing erosion. For example, the vent valve 23 may include a vent plug with an oleophobic membrane or a spring-loaded check valve 25, which can be set according to actual needs. This embodiment does not limit the specific type of vent valve 23.

[0040] Optionally, in this embodiment, the range extender system further includes a return channel 133, which is located at the bottom of the motor cavity 22 and communicates with the balance chamber 31. This ensures that even if the first seal 30 experiences minor leakage due to aging, resulting in fluid accumulation in the balance chamber 31, the accumulated fluid can be transported downwards by gravity to the return channel 133 at the bottom of the motor cavity 22. The fluid is then automatically and promptly discharged through the return channel 133, flowing back to the oil sump at the bottom of the motor cavity 22. This prevents residual oil in the balance chamber 31, keeping it a dry area for better pressure balance. Furthermore, since the engine oil is typically made of the same material as the cooling lubricant, this embodiment prevents oil accumulation in the balance chamber 31 from affecting the seal and enables oil recycling, avoiding waste and pollution.

[0041] Therefore, this embodiment of the application, through the vent 131 and the return channel 133, allows trace amounts of oil mist that are not discharged in time to enter the vent 131 and be intercepted by the liquid-blocking vent 322. The intercepted oil is then transferred to the oil sump in the motor cavity 22 through the return channel 133, forming a dual protection mechanism of active oil discharge and passive liquid blocking, significantly improving the durability of the sealing system. For example, during long-term high-load operation of the range extender, the temperature of the balance chamber 31 may rise, and oil vapor evaporation may intensify. At this time, the liquid-blocking function of the liquid-blocking vent 322 can effectively prevent oil vapor from condensing into liquid oil in the motor cavity 22, maintaining the stability of the motor lubricating coolant composition. The oil can then be recycled back to the oil sump in the motor cavity 22 through the return channel 133, avoiding pollution and waste, and achieving recycling and reuse. Furthermore, it reduces the risk of the first seal 30 and the second seal 40 being corroded by oil, improves their working conditions, and extends their service life. Furthermore, the automatic oil drainage mechanism of the return channel 133 reduces corrosion or other malfunctions that may be caused by oil accumulation, thereby improving the maintenance-free operation cycle of the range extender system.

[0042] In this embodiment, optionally, the motor structure includes a rotor shaft 24, which is disposed at the center of the motor cavity 22 and divides the motor cavity 22 into a first cavity 221 and a second cavity 222. The first cavity 221 is located above the second cavity 222. A vent 131 communicates with the first cavity 221, and a return fluid channel 133 communicates with the second cavity 222. For example, the rotor shaft 24 may be located at the center of the motor cavity 22, extending within the motor cavity 22 and dividing the motor cavity 22 into an upper first cavity 221 and a lower second cavity 222. The upper first cavity 221 may form an upper gas phase region, and the lower second cavity 222 may form a lower oil sump region. This embodiment of the application connects the vent 131 to the upper gas phase zone of the first cavity 221, avoiding the oil sump surface in the lower cavity, the oil splash area of ​​the rotor 27, and the oil foam layer. This prevents liquid oil or oil droplets from being carried into the vent 131 by the airflow, causing blockage and ventilation failure. It also prevents trace amounts of oil mist from the engine side from entering the stator 26 windings or terminal area of ​​the motor structure, causing insulation risks. Furthermore, a return liquid channel is provided that connects to the second cavity 222 of the lower cavity oil sump zone. This facilitates oil recovery under gravity without introducing gaseous media into the return liquid path, preventing back pressure and avoiding return liquid splashing onto electrical components in the first cavity 221 of the upper cavity.

[0043] In this embodiment, because the balance chamber 31 maintains a balance or near-balance with atmospheric pressure through the balance path formed by the vent 131 and the first cavity 221 of the motor cavity 22, the pressure difference on both sides of the first seal 30 is small, effectively suppressing oil leakage and eliminating the cause of failure due to pressure imbalance. Simultaneously, a small amount of oil seeping into the balance chamber 31 from the motor-side oil seal (i.e., the second seal 40), or condensed oil vapor entering through the vent 131, can accumulate at the bottom of the balance chamber 31 under gravity and be automatically and promptly discharged back to the generator oil sump through the oil return structure of the return channel 133, ensuring no residual oil in the balance chamber 31 and maintaining its dry zone function.

[0044] Optionally, in this embodiment, the bottom of the connecting end plate 13 is provided with a protruding return fluid portion 134. The range extender system includes a return fluid pipe (not shown), which is disposed within the return fluid portion 134, and the inner wall of the return fluid pipe forms a return fluid channel 133; or, the return fluid channel 133 is formed within the return fluid portion 134. In this way, the return fluid pipe can be embedded in the return fluid portion 134 to form the return fluid channel 133. The inner wall of the return fluid pipe makes the return fluid channel 133 have a high degree of smoothness, reducing the risk of condensate sticking to the wall and improving the smoothness of fluid flow in the return fluid channel 133. Alternatively, the return fluid channel 133 can be directly formed by drilling in the return fluid portion 134, which can make the return fluid channel 133 have a larger cross-sectional area, reducing the risk of oil blockage. It is also low-cost, does not require additional complex external pipelines or devices, and does not significantly increase the overall size and weight of the range extender structure, which is conducive to the compact layout of the power system in the vehicle.

[0045] For example, in this embodiment, the protruding venting portion 132 and the liquid return portion 134 can be symmetrically arranged relative to the axial direction of the crankshaft 12, and the protrusion heights of the venting portion 132 and the liquid return portion 134 can be the same, so that the connecting end plate 13 of the cylinder block 11 has good structural stability and reliability. Alternatively, the venting portion 132 and the liquid return portion 134 can also be asymmetrically arranged, and their protrusion heights can also be different; this embodiment does not limit this arrangement.

[0046] In this embodiment, optionally, the range extender system further includes a one-way valve 25, which is connected to the side of the return channel 133 away from the cavity. This allows the one-way valve 25 to control the discharge of oil from the return channel 133. Specifically, the one-way valve 25 has an opening threshold. When the oil in the return channel 133 accumulates to a preset volume or weight, the oil pushes open the valve of the one-way valve 25, forming a discharge pulse. After the oil is discharged, the one-way valve 25 automatically closes, which helps maintain the dry zone function of the balance chamber 31. Furthermore, the one-way valve 25 provides a good sealing function for the return channel 133, preventing the oil in the oil sump of the motor cavity 22 from surging during large pitches, rapid acceleration / deceleration, or agitation by the rotor 27. This prevents the surging oil or foam from potentially flowing back into the balance chamber 31 along the return channel 133, thus achieving a good sealing effect on the balance chamber 31.

[0047] For example, in the embodiments of this application, the one-way valve 25 can be an umbrella valve, a reed valve, a ball check valve, or a sleeve valve, which can be set according to actual needs. The specific type of the one-way valve 25 is not limited in the embodiments of this application.

[0048] In this embodiment of the application, for example, the umbrella valve may include a valve plate made of spring steel, which is mounted on the pipe wall of the return channel 133 via a hinge shaft. Under normal conditions, the one-way valve 25 can cover the valve port by its own weight or a slight pre-tightening force. When the oil level at the bottom of the balance chamber 31 generates sufficient pressure, the oil pushes open the one-way valve 25 and flows into the generator oil sump. After the oil has drained, the valve plate automatically resets and closes, so that the balance chamber 31 has good sealing performance.

[0049] Optionally, in this embodiment, the return channel 133 is inclined. This allows the oil to be transported more smoothly along the return channel 133 to the oil sump at the bottom of the motor cavity 22, reducing the risk of oil getting stuck in the return channel 133. Specifically, the inclined return channel 133 can provide a constant downward component for the oil, allowing the oil to flow along the slope of the return channel 133.

[0050] For example, in this embodiment of the application, the tilt angle of the return channel 133 can be 80°, 85°, 87°, 75° or 70°, which can be set according to actual needs. In this embodiment of the application, the specific value of the tilt angle of the return channel 133 is not limited.

[0051] This application also proposes a vehicle that includes a range extender system.

[0052] For example, in the embodiments of this application, the vehicle may include a pure electric vehicle, a hybrid vehicle, a range-extended vehicle, or a fuel vehicle. The vehicle type may also include a small car, a mid-size car, a sedan, a truck, a trailer, a CDV (CarDerived Van), an MPV (multi-Purpose Vehicle), or an SUV (Sport Utility Vehicle). The specific type of vehicle is not limited in the embodiments of this application.

[0053] In summary, the vehicle and range extender system of this application embodiment may include at least the following advantages: In this embodiment, the range extender system includes: an engine structure, a motor structure, a first seal 30, and a second seal 40; the engine structure includes a cylinder block 11 and a crankshaft 12, one end of the cylinder block 11 is provided with a connecting end plate 13, the crankshaft 12 is disposed in the cylinder block 11 and extends out of the connecting end plate 13, and a gap is provided between the crankshaft 12 and the connecting end plate 13; the motor structure includes a housing 21, the housing 21 is connected to the connecting end plate 13 and surrounds to form a motor cavity 22, and the crankshaft 12 extends into the motor cavity 22; the first seal 30 and the second seal 40 are respectively located in the gap and connected between the crankshaft 12 and the connecting end plate 13, and a balance cavity 31 is provided between the first seal 30 and the second seal 40; a vent 131 is provided in the connecting end plate 13, the vent 131 communicates with the balance cavity 31, and the vent 131 communicates with the motor cavity 22, and the motor cavity 22 communicates with the outside. The first seal 30 and the second seal 40 are respectively located within the gap and connected between the crankshaft 12 and the connecting end plate 13. That is, the first seal 30 and the second seal 40 can be coaxially spaced along the axial direction of the crankshaft 12. In this way, the spaced first seal 30 and the second seal 40 form a balance chamber 31, which achieves pressure balance with the external atmospheric pressure through the air passage 131 and the motor cavity 22. Thus, when there is an air pressure imbalance between the engine structure and the motor structure, the atmospheric pressure connected by the balance chamber 31 balances the air pressure in the engine structure or the motor structure, which greatly reduces the risk of cross-contamination between the engine oil in the engine structure and the lubricating coolant in the motor structure. It also reduces the risk of the engine oil in the engine structure and the lubricating coolant in the motor structure mixing, which may affect the lubricating coolant and cause its temperature to rise or its lubrication performance to decrease. This ensures that the lubricating coolant maintains good lubrication and cooling performance for the motor structure.

[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0055] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A range extender system, characterized in that, The range extender system includes: an engine structure, an electric motor structure, a first seal (30), and a second seal (40). The engine structure includes a cylinder block (11) and a crankshaft (12). One end of the cylinder block (11) is provided with a connecting end plate (13). The crankshaft (12) is disposed inside the cylinder block (11) and extends out of the connecting end plate (13). There is a gap between the crankshaft (12) and the connecting end plate (13). The motor structure includes a housing (21), which is connected to the connecting end plate (13) and encloses to form a motor cavity (22), and the crankshaft (12) extends into the motor cavity (22); The first seal (30) and the second seal (40) are located in the gap and are respectively connected to the crankshaft (12) and the connecting end plate (13), and a balance cavity (31) is provided between the first seal (30) and the second seal (40). The connecting end plate (13) is provided with a ventilation channel (131), which is connected to the balance chamber (31) and the motor cavity (22), which is connected to the outside.

2. The range extender system according to claim 1, characterized in that, The connecting end plate (13) is provided with a vent (132) protruding toward the motor cavity (22), and the vent (131) is disposed in the vent (132); The ventilation channel (131) includes a connecting part (321) and a liquid-blocking and air-permeable part (322) that are interconnected. The connecting part (321) is connected to the balance chamber (31), and the liquid-blocking and air-permeable part (322) is connected to the motor cavity (22).

3. The range extender system according to claim 2, characterized in that, The liquid-blocking and air-permeable part (322) includes at least one bent air guide plate (323). And / or, the connecting portion (321) extends radially, and the liquid-blocking and air-permeable portion (322) extends axially from one end of the connecting portion (321).

4. The range extender system according to claim 1, characterized in that, The top of the housing (21) is provided with a vent valve (23), which is located near the connecting end plate (13). The motor cavity (22) is connected to the outside through the vent valve (23).

5. The range extender system according to claim 1, characterized in that, The range extender system also includes a return channel (133), which is located at the bottom of the motor cavity (22). The return channel (133) is connected to the balance chamber (31) and the motor cavity (22).

6. The range extender system according to claim 5, characterized in that, The motor structure includes a rotor shaft (24), which is located at the center of the motor cavity (22) and divides the motor cavity (22) into a first cavity (221) and a second cavity (222). The first cavity (221) is located above the second cavity (222). The ventilation channel (131) is connected to the first cavity (221), and the return channel (133) is connected to the second cavity (222).

7. The range extender system according to claim 5, characterized in that, The bottom of the connecting end plate (13) is provided with a protruding return liquid part (134). The range extender system includes a return liquid pipe, which is disposed in the return liquid part (134). The inner wall of the return liquid pipe forms the return liquid channel (133). Alternatively, the return channel (133) may be located within the return section (134).

8. The range extender system according to claim 5, characterized in that, The range extender system also includes a one-way valve (25) connected to the side of the return channel (133) away from the cavity.

9. The range extender system according to claim 5, characterized in that, The return channel (133) is inclined.

10. A vehicle, characterized in that, The vehicle includes the range extender system according to any one of claims 1-9.

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