Direct connection type range extender and hybrid electric vehicle

Abstract

The embodiment of the utility model discloses a direct-connection type range extender and a hybrid electric vehicle, and the direct-connection type range extender comprises an engine which comprises a crankshaft; the generator comprises a generator housing, which is provided with a centering shaft; the rotor bracket is in transmission connection with the crankshaft and sleeves the periphery of the centering shaft; one of the crankshaft and the centering shaft is provided with a positioning hole, and the other one is provided with a positioning part; and the positioning hole is matched with the positioning part in shape, so that the positioning part is embedded in the positioning hole. According to the utility model, the centering degree among the crankshaft, the generator shell and the rotor bracket is improved in the installation process, the precision requirement of installation equipment is reduced, and the installation difficulty of the generator on an engine is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of hybrid electric vehicles, in particular to a direct-connected range extender and a hybrid electric vehicle. Background Art

[0002] Faced with the increasingly severe energy situation and stricter automobile emission standards, new energy electric vehicles have emerged. However, due to the limited power battery capacity, matching with a range extender is an effective means to solve the problem of electric vehicle endurance. As an independent system added to pure electric vehicles, the range extender is limited in weight and space. In order to solve the problem of limited longitudinal size of the range extender, a method of installing the generator on the engine housing and directly connecting the generator rotor bracket to the engine crankshaft has emerged.

[0003] During the installation of the generator on the engine, the engine crankshaft, rotor bracket and generator housing need to be centered so that the rotor is installed in a suitable position to avoid the rotor on the rotor bracket being poorly positioned in the generator housing and causing friction with the stator in the electrode housing.

[0004] However, during the installation process, due to the large tolerance, it is difficult to accurately insert the cylindrical positioning hole into the positioning hole on the engine crankshaft, and it is difficult to accurately center the engine crankshaft, rotor bracket and housing, which affects the performance of the range extender. Utility Model Content

[0005] The embodiment of the utility model provides a direct-connected range extender and a hybrid vehicle, so as to improve the degree of centering among a crankshaft, a generator housing and a rotor bracket during installation, and reduce the difficulty of installing the generator on the engine.

[0006] In order to solve the above technical problems, the embodiments of the present utility model disclose the following technical solutions:

[0007] In one aspect, a direct-connected range extender is provided, comprising:

[0008] An engine comprising a crankshaft (100);

[0009] A generator comprising:

[0010] a generator housing having a centering shaft;

[0011] A rotor support, which is drivingly connected to the crankshaft and sleeved on the outer periphery of the centering shaft;

[0012] Wherein, one of the crankshaft and the centering shaft has a positioning hole, and the other has a positioning portion; the positioning hole matches the positioning portion in shape so that the positioning portion can be embedded in the positioning hole.

[0013] In addition to or as an alternative to one or more of the features disclosed above, the positioning hole is arranged at an end of the crankshaft close to the centering axis;

[0014] The positioning portion is disposed at an end portion of the centering shaft close to the crankshaft direction.

[0015] In addition to or as an alternative to one or more of the features disclosed above, the diameter of the positioning hole gradually decreases in a direction away from the positioning portion, and the outer diameter of the positioning portion gradually increases in a direction away from the positioning hole.

[0016] In addition to or instead of one or more of the features disclosed above, the rotor bracket includes a connected direct connection portion and a rotor mounting portion, the direct connection portion having a center hole extending axially therethrough, the direct connection portion being sleeved on the outer periphery of the centering shaft, and the positioning portion being accommodated in the center hole.

[0017] In addition to or as an alternative to one or more of the features disclosed above, the crankshaft has a protrusion at one end close to the rotor support, and the protrusion is embedded in the center hole of the direct connection portion.

[0018] In addition to or as an alternative to one or more of the features disclosed above, the invention further comprises:

[0019] A spring washer, at least one of which is sandwiched between the crankshaft and the rotor support.

[0020] In addition to or as an alternative to one or more of the features disclosed above, the spring washer includes at least one of an open spring washer, a wave spring washer, or a disc spring washer.

[0021] In addition to or as an alternative to one or more of the features disclosed above, the generator housing further comprises:

[0022] A centering cylinder coaxial with the crankshaft;

[0023] A side plate, which is arranged around the outer periphery of the centering cylinder;

[0024] An end plate is arranged at one end of the side plate away from the engine, and the end plate connects the side plate and the centering cylinder;

[0025] A connecting flange, which is arranged at one end of the side plate close to the engine, and the side plate is fixedly connected to the engine through the connecting flange;

[0026] The side plates, the end plates, the connecting flanges and the centering barrel are arranged to form a receiving cavity, the rotor bracket is at least partially received in the receiving cavity, and the centering shaft is arranged on a side of the centering barrel facing the crankshaft.

[0027] In addition to or as an alternative to one or more of the features disclosed above, the outer peripheral surface of the side plate is provided with a plurality of second mounting grooves that completely penetrate the side plate in the axial direction;

[0028] The third fastener passes through the second mounting groove to fix the connecting flange on the engine.

[0029] On the other hand, a hybrid vehicle is further disclosed. In addition to or as an alternative to one or more of the features disclosed above, the hybrid vehicle includes a direct-connected range extender as described in any one of the above items.

[0030] One of the above technical solutions has the following advantages or beneficial effects: First, the present application sets mutually matching positioning holes and positioning parts at the position where the crankshaft of the engine is connected to the rotor bracket of the motor, and the inclined surfaces between the positioning holes and the positioning parts cooperate so that the connection between the generator and the engine can be completed without high centering requirements during the installation of the generator, thereby reducing the precision requirements for the installation equipment, reducing the difficulty of installing the generator on the engine, and improving the efficiency and reliability of manufacturing. In the process of installing the generator on the engine, the positioning part enters the positioning hole along the column of the depth direction of the positioning hole, and the inclined inner peripheral surface of the positioning hole abuts against the inclined outer peripheral surface of the positioning part. The inclined inner peripheral surface and the outer peripheral surface cooperate with each other to have a guiding and supporting effect, which improves the degree of centering between the crankshaft, the generator housing and the rotor bracket, and further reduces the difficulty of installation. Secondly, the present application sleeves the rotor bracket on the outer periphery of the centering shaft, and the rotor bracket is centered with the generator housing during the generator assembly process. This structure avoids the need to perform double centering of the crankshaft with the generator housing and the rotor bracket respectively during the installation of the generator on the engine in the prior art, and avoids mutual friction between the rotor on the rotor bracket and the stator on the generator housing due to improper installation, further reducing the difficulty of installation and improving manufacturing efficiency and reliability.

[0031] The present application sets a spring washer between the crankshaft and the rotor bracket. On the one hand, the spring washer replaces the gasket structure set according to the manufacturing tolerance of the crankshaft and the rotor bracket in the prior art. The spring washer plays a role in reducing the gap between the crankshaft and the rotor bracket and improving the fit between the two. On the other hand, the spring washer can also play a role in increasing the assembly preload between the crankshaft and the rotor bracket and improving the centering accuracy between the crankshaft and the rotor bracket. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The technical solutions and other beneficial effects of the present invention will be made apparent by describing in detail the specific embodiments of the present invention in conjunction with the accompanying drawings.

[0033] Figure 1It is a structural schematic diagram of a direct-connected range extender provided according to an embodiment of the utility model.

[0034] Figure 2 It is a cross-sectional view of a direct-connected range extender provided according to an embodiment of the utility model.

[0035] Figure 3 The figure is a schematic diagram of the explosion structure of a direct-connected range extender provided according to an embodiment of the utility model.

[0036] Figure 4 It is a schematic diagram of an exploded structure from another perspective of a direct-connected range extender provided according to an embodiment of the utility model.

[0037] Figure 5 It is a structural schematic diagram of a rotor bracket in a direct-connected range extender provided according to an embodiment of the utility model.

[0038] Figure 6 It is a schematic diagram of a crankshaft structure in a direct-connected range extender provided according to an embodiment of the utility model.

[0039] In the figure: 100-crankshaft; 101-positioning hole; 110-crankshaft body; 120-connecting part; 1201-first end face; 121-screw hole; 130-protrusion; 1301-second end face; 200-generator housing; 201-accommodating chamber; 210-side plate; 220-centering cylinder; 221-guide hole; 230-connecting flange; 231-through area; 240-centering shaft; 241-positioning part; 250-end plate; 300-rotor bracket; 310-direct connection part; 311-center hole; 312-fixing hole; 320-rotor mounting part; 400-spring washer. DETAILED DESCRIPTION

[0040] The present invention is further described in detail below in conjunction with the accompanying drawings and specific implementations. It should be understood that the specific implementations described in this specification are only for explaining the present invention, and are not intended to limit the present invention.

[0041] Figure 1 and Figure 2 The structural schematic diagram and cross-sectional view of a direct-connected range extender provided in one embodiment of the present application are respectively shown. The direct-connected range extender includes an engine and a generator, the engine includes an engine housing (not shown in the figure) and a crankshaft 100 extending from the engine housing, and the generator is mounted on the engine housing. The generator includes a generator housing 200 and a rotor support 300, the generator housing 200 has a centering shaft 240, the rotor support 300 is at least partially accommodated in the generator housing 200, the rotor support 300 is sleeved on the outer periphery of the centering shaft 240, and the rotor support 300 is drivingly connected to the crankshaft 100.

[0042] Among them, a positioning hole 101 is provided at the end of the crankshaft 100 close to the centering shaft 240, and a positioning portion 241 is provided at the end of the centering shaft 240 close to the crankshaft 100. The aperture of the positioning hole 101 gradually decreases in the direction away from the centering shaft 240, so that the positioning hole 101 has an inner circumferential surface whose inner diameter gradually decreases in the direction away from the centering shaft 240, and the outer diameter of the positioning portion 241 gradually increases in the direction away from the crankshaft 100, so that the positioning portion 241 has a conical outer circumferential surface matched with the inner circumferential surface. The positioning portion 241 is embedded in the positioning hole 101, and the inner circumferential surface of the positioning hole 101 abuts against the outer circumferential surface of the positioning portion 241.

[0043] The positioning portion 241 is embedded in the positioning hole 101, and the crankshaft 100 and the centering shaft 240 are centered. Because the rotor bracket 300 and the centering shaft 240 are coaxially connected, the crankshaft 100 and the rotor bracket 300 are centered synchronously, so as to facilitate the subsequent process of fixing the crankshaft 100 and the rotor bracket 300. When the engine outputs power, the crankshaft 100 drives the rotor bracket 300 to rotate, so that the generator works to generate electricity for driving the hybrid vehicle motor, and the power transmission between the engine and the generator is realized.

[0044] The positioning hole 101 and the positioning portion 241 of the present application use a centering method that cooperates with an inclined inner circumferential surface and an inclined outer circumferential surface. On the one hand, this reduces the difficulty of production and the precision requirements for installation equipment, thereby reducing production costs. On the other hand, it avoids double centering during the installation process while improving the centering degree of the crankshaft 100, the rotor bracket 300 and the engine housing, thereby improving the reliability of the product.

[0045] It should be noted that in this embodiment, the positioning hole 101 is provided on the crankshaft 100, and the positioning portion 241 is provided on the centering shaft 240. In other embodiments, the positioning hole 101 may also be provided on the centering shaft 240, and the positioning portion 241 may be provided on the crankshaft 100, which is not specifically limited here.

[0046] Figure 3 and Figure 4The exploded structural schematic diagrams of different perspectives of a direct-connected range extender provided by an embodiment of the present application are respectively shown. The generator housing 200 also includes a centering barrel 220, a side plate 210, an end plate 250 and a connecting flange 230. Among them, the centering barrel 220 is a cylindrical structure with an open opening, and the centering barrel 220 is coaxially arranged with the crankshaft 100. The opening of the centering shaft 240 faces the direction away from the crankshaft 100. The centering shaft 240 is arranged at the end of the centering barrel 220 close to the crankshaft 100 and is fixedly connected to the centering barrel 220. The side plate 210 is a cylindrical structure with openings at both ends, and the side plate 210 is sleeved on the outer periphery of the centering barrel 220. The annular end plate 250 is arranged at one end of the side plate 210 away from the crankshaft 100, and the end plate 250 connects the side plate 210 and the centering barrel 220. The connecting flange 230 is provided at an opening on one side of the side plate 210 facing the crankshaft 100, and a plurality of evenly arranged connecting holes 232 are axially provided on the outer edge of the connecting flange 230. The connecting holes 232 are used for fixed connection between the connecting flange 230 and the side plate 210, and for fixed connection between the connecting flange 230 and the engine housing. A through area 231 is provided at the center of the connecting flange 230, which penetrates along its thickness. The positioning portion 241 of the centering shaft 240 is embedded in the positioning hole 101 of the crankshaft 100 to realize the centering of the connecting hole 232 of the connecting flange 230 with the mounting hole on the engine housing. The centering cylinder 220, the side plate 210, the end plate 250 and the connecting flange 230 are surrounded inside the generator housing 200 to form a receiving chamber 201, and at least part of the rotor bracket 300 and other components such as the stator and the rotor are received in the receiving chamber 201. Parts of the rotor support 300 and the centering shaft 240 extend through the through-region 231 of the connecting flange 230 to be connected to the crankshaft 100 .

[0047] Specifically, the outer peripheral surface of the side plate 210 is provided with a plurality of first mounting grooves 2101 partially penetrating the side plate 210 in the axial direction and a second mounting groove 2102 completely penetrating the side plate, and the first mounting grooves 2101 and the second mounting grooves 2102 correspond to the connecting holes 232 on the connecting flange 230. Among them, the first mounting groove 2101 partially penetrates the side plate 210 at one end of the side plate 210 away from the connecting flange 230, and a through hole penetrating the side plate 210 in the axial direction is provided in the part of the side plate 210 corresponding to the first mounting groove 2101 in the axial direction, and the second fastener of the bolt structure passes through the through hole and is screwed into the connecting hole 232 corresponding to the first mounting groove 2101, so as to realize the fixed connection between the connecting flange 230 and the side plate 210. The third fastener of the bolt structure passes through the second mounting groove 2102, the connecting hole 232 and the mounting hole on the engine casing in sequence, so as to realize the fixed connection between the connecting flange 230 and the engine casing, thereby enabling the generator to be installed on the engine casing. This connection method achieves a close fit between the connecting flange 230 and the engine housing and side panels 210 on both sides, avoiding the occurrence of gaps between the three, thereby better achieving the centering of the crankshaft 100, the rotor bracket 300 and the generator housing 200 while the positioning portion 241 is embedded in the positioning hole 101.

[0048] Figure 5 The schematic diagram of the structure of the rotor support 300 in a direct-connection range extender provided according to an embodiment of the utility model is shown. The rotor support 300 includes a direct connection portion 310 and a rotor mounting portion 320. The direct connection portion 310 is provided with a center hole 311 extending axially therethrough at its center position, so that the direct connection portion 310 can be sleeved on the outer periphery of the centering shaft 240. A plurality of fixing holes 312 are also provided on the outer periphery of the center hole 311, which extend circumferentially around the center hole 311. The fixing holes 312 extend circumferentially through the direct connection portion 310, and the fixing holes 312 are used to be fixedly connected to the crankshaft 100 through a first fastener. A plurality of guide holes 221 corresponding to the fixing holes 312 are provided on the centering cylinder 220 at positions corresponding to the fixing holes 312, so that after the centering shaft 240 and the crankshaft 100 are centered, the first fastener passes through the opening of the centering cylinder 220 and the guide holes 221 to fix the rotor bracket 300 and the crankshaft 100. The rotor mounting portion 320 is a cylindrical structure, which is sleeved on the outer periphery of the centering cylinder 220 and connected to the direct connection portion 310. The rotor mounting portion 320 is used for mounting the rotor, and a plurality of rotors are mounted on the outer periphery of the rotor mounting portion 320. A plurality of stators are provided on the inner side wall of the side plate 210 at positions corresponding to the rotor mounting portion 320. The stator and the rotor are arranged opposite to each other, so that when the crankshaft 100 drives the rotor bracket 300 to rotate around its axis, the magnetic fields of the stator and the rotor interact to generate electricity.

[0049] Figure 6A schematic diagram of the structure of a crankshaft 100 in a direct-connected range extender provided according to an embodiment of the utility model is shown, and the crankshaft 100 includes a crankshaft body 110, a connecting portion 120 and a protruding portion 130. The crankshaft body 110 is a roller-shaped structure. The connecting portion 120 is a disc-shaped structure, and the connecting portion 120 is arranged at the end of the crankshaft body 110. The end face of the connecting portion 120 facing away from the crankshaft body 110 is a first end face 1201. The protruding portion 130 is convexly arranged on the first end face 1201 of the connecting portion 120, and the end face of the protruding portion 130 facing away from the crankshaft body 110 is a second end face 1301, and the second end face 1301 protrudes from the first end face 1201. The positioning hole 101 is arranged at the center of the protruding portion 130. The end face of the direct connection portion 310 facing the crankshaft is a third end face 3101. The first end face 1201 of the connecting portion 120 abuts against the third end face of the direct connection portion 310. The outer diameter of the positioning portion 241 is smaller than the diameter of the centering shaft 240, so that the end of the centering shaft 240 facing the crankshaft 100 has a fourth end face 2401 surrounding the positioning portion 241, and the second end face 1301 of the protruding portion 130 abuts against the fourth end face 2401 of the centering shaft 240. The positioning portion 241 is accommodated in the center hole 311, the inner diameter of the center hole 311 is matched with the outer diameter of the protruding portion 130, the protruding portion 130 is embedded in the center hole 311 of the direct connection portion 310, and the positioning portion 241 arranged on the fourth end face 2401 is embedded in the positioning hole 101 at the center position of the protruding portion 130. The interlaced connection structure further improves the connection effect between the crankshaft 100 and the rotor support 300 , as well as the degree of centering among the crankshaft 100 , the rotor support 300 and the centering shaft 240 .

[0050] Furthermore, a plurality of screw holes 121 corresponding to the fixing holes 312 of the rotor bracket 300 are provided on the first end surface 1201 of the connecting portion 120, so that the first fastener can fix the crankshaft 100 and the rotor bracket 300 through the fixing holes 312 and the screw holes 121, thereby realizing the transmission between the engine and the generator.

[0051] Continue to refer to Figure 2 , Figure 3As shown, the direct-connected range extender of the present application also includes a spring washer 400, which is sandwiched between the crankshaft 100 and the rotor bracket 300. Due to tolerance or thermal barrier and shrinkage of materials, a gap will be generated between the crankshaft 100 and the rotor. The spring washer 400 replaces the gasket structure set between the crankshaft 100 and the rotor bracket 300 according to the tolerance in the prior art. The spring washer 400 plays a role in reducing the gap between the crankshaft 100 and the rotor bracket 300 and improving the fit between the two. And the spring washer 400 has elastic force in the axial direction to increase the assembly preload between the crankshaft 100 and the rotor bracket 300, thereby improving the connection effect between the crankshaft 100 and the rotor bracket 300 and improving the reliability of the product. In the process of installing the generator on the engine housing, the spring washer 400 also plays a role in absorbing the impact load of the rotor bracket 300 on the crankshaft 100 during the installation process, avoiding the damage of the rotor bracket 300 or the crankshaft 100 caused by the collision during the installation, and improving the product yield.

[0052] In this embodiment, the spring washer 400 is a wave spring washer. In other embodiments, the spring washer 400 is an open spring washer or a disc spring washer, etc., which are other types of spring washers that are in a sheet shape after being compressed and have no overlap in their own structure, which is not specifically limited here.

[0053] In this embodiment, the spring washer 400 is sleeved on the outer periphery of the protrusion 130. During the process of fastening the crankshaft 100 and the rotor support 300 by the first fastener, the spring washer 400 is gradually flattened by force until the crankshaft 100 and the rotor support 300 are fitted together through the spring washer 400. The process of the spring washer 400 being gradually flattened by force cooperates with the positioning hole 101 and the positioning portion 241 structure of the tapered cross section, so that the crankshaft 100 and the rotor support 300 are further centered, compensating for the deviation displacement of the rotor support 300 relative to the crankshaft 100 caused by tolerance or other reasons after the generator is installed, thereby improving the centering accuracy between the rotor support 300 and the crankshaft 100.

[0054] On the other hand, the present application further discloses a hybrid vehicle, which, in addition to or instead of one or more of the features disclosed above, includes the above-mentioned direct-connected range extender, which provides driving power for the hybrid vehicle.

[0055] The above-mentioned embodiments only express several implementation methods of the present application. It should be noted that, for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present application, which all belong to the protection scope of the present application. Therefore, the protection scope of the patent of this application shall be subject to the attached claims.

Claims

1. A direct-connected range extender, characterized in that: include: An engine comprising a crankshaft (100); A generator comprising: A generator housing (200) having a centering shaft (240); A rotor support (300) which is drivingly connected to the crankshaft (100) and sleeved on the outer periphery of the centering shaft (240); Wherein, one of the crankshaft (100) and the centering shaft (240) has a positioning hole (101), and the other has a positioning portion (241); the positioning hole (101) and the positioning portion (241) are matched in shape so that the positioning portion (241) can be embedded in the positioning hole (101).

2. The direct-connected range extender according to claim 1, characterized in that: The positioning hole (101) is arranged at an end of the crankshaft (100) close to the centering axis (240); The positioning portion (241) is arranged at an end of the centering shaft (240) close to the crankshaft (100).

3. The direct-connected range extender according to claim 1 or 2, characterized in that: The diameter of the positioning hole (101) gradually decreases in a direction away from the positioning portion (241), and the outer diameter of the positioning portion (241) gradually increases in a direction away from the positioning hole (101).

4. The direct-connected range extender according to claim 1, characterized in that: The rotor support (300) comprises a directly connected portion (310) and a rotor mounting portion (320) connected to each other, wherein the directly connected portion (310) has a center hole (311) extending through the directly connected portion (310) along its axial direction, the directly connected portion (310) is sleeved on the outer periphery of the centering shaft (240), and the positioning portion (241) is accommodated in the center hole (311).

5. The direct-connected range extender according to claim 4, characterized in that: The crankshaft (100) has a protruding portion (130) at one end close to the rotor support (300), and the protruding portion (130) is embedded in the central hole (311) of the direct connection portion (310).

6. The direct-connected range extender according to claim 1, characterized in that: Also includes: A spring washer (400), at least one of the spring washers (400) is sandwiched between the crankshaft (100) and the rotor support (300).

7. The direct-connected range extender according to claim 6, characterized in that: The spring washer (400) comprises at least one of an open spring washer, a wave spring washer or a disc spring washer.

8. The direct-connected range extender according to claim 1, characterized in that: The generator housing (200) further comprises: A centering cylinder (220) coaxial with the crankshaft (100); A side plate (210) is arranged around the outer periphery of the centering cylinder (220); an end plate (250) disposed at an end of the side plate (210) away from the engine, the end plate (250) connecting the side plate (210) and the centering cylinder (220); A connecting flange (230) is arranged at one end of the side plate (210) close to the engine, and the side plate (210) is fixedly connected to the engine via the connecting flange (230); The side plate (210), the end plate (250), the connecting flange (230) and the centering cylinder (220) are arranged to form a receiving cavity (201), the rotor bracket (300) is at least partially received in the receiving cavity (201), and the centering shaft (240) is arranged on a side of the centering cylinder (220) facing the crankshaft (100).

9. The direct-connected range extender according to claim 8, characterized in that: The outer peripheral surface of the side plate (210) is provided with a plurality of second installation grooves (2102) which completely penetrate the side plate (210) in the axial direction; The third fastener passes through the second mounting groove (2102) to fix the connecting flange (230) on the engine.

10. A hybrid vehicle, characterized in that: It comprises a direct-connected range extender as described in any one of claims 1 to 9.

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