Range extender and vehicle

Abstract

The utility model discloses a range extender and a vehicle, and relates to the technical field of vehicles, and the range extender comprises an engine provided with a crankshaft; the generator comprises a machine shell, a stator and a rotor, the stator and the rotor are arranged in the machine shell, the rotor is connected with the crankshaft, the machine shell comprises a shell and an end plate, a containing cavity with openings in the two ends is formed in the shell, the stator and the rotor are arranged in the containing cavity, and the end plate is arranged in one opening and integrally formed with the shell; according to the technical scheme, the overall size of the range extender is reduced, the number of parts of the range extender is reduced, and the overall structural strength of the range extender is improved.

Description

Technical Field

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

[0002] At present, extended-range vehicles have been increasingly widely used because they combine the advantages of long endurance of internal combustion engine systems and low energy consumption of electric drive systems. However, the existing range extenders have a high overall cost because they integrate two power sources at the same time, have many parts and are complex to assemble. In addition, the complex structure also affects the compactness of the range extender structure, making it difficult to arrange the range extender on the vehicle. Utility Model Content

[0003] The main purpose of the utility model is to provide a range extender and a vehicle, aiming to reduce the overall size and the number of parts of the range extender and to improve the overall structural strength of the range extender.

[0004] In order to achieve the above-mentioned object, the utility model proposes a range extender, comprising:

[0005] an engine having a crankshaft; and

[0006] A generator, the generator includes a casing, a stator and a rotor arranged inside the casing, the rotor is connected to the crankshaft, the casing includes a shell and an end plate, the shell has an interior forming a receiving cavity with openings at both ends, the stator and the rotor are arranged in the receiving cavity, the end plate is arranged at one of the openings and is integrally formed with the shell.

[0007] In one embodiment, the range extender further comprises:

[0008] A junction box, disposed on a side of the housing and connected to the accommodating cavity;

[0009] The connection terminal is arranged in the connection box and is conductively connected to the stator.

[0010] In one embodiment, the junction box and the housing are integrally formed.

[0011] In one embodiment, the range extender further comprises a front cover, which is disposed at the other opening and is detachably connected to the housing, and the housing is connected to the engine via the front cover.

[0012] In one embodiment, the rotor is directly connected to the crankshaft.

[0013] In one embodiment, a first flange is protrudingly provided at one end of the crankshaft, a second flange is protrudingly provided at one end of the rotor, and the first flange is connected to the second flange by screw locking.

[0014] In one embodiment, the end plate is provided with a support hole, the support hole is communicated with the accommodating cavity, and one end of the rotor is rotatably connected to the support hole.

[0015] In one embodiment, the range extender further includes a bearing, which is disposed in the support hole, and the rotor is rotatably connected to the end plate via the bearing; and / or, the range extender further includes a resolver, which is disposed in the support hole and connected to the rotor.

[0016] In one embodiment, the range extender further includes a sealing cover, which is arranged on a side of the support hole away from the rotor, and the sealing cover is sealed and connected to the support hole; and / or the periphery of the support hole protrudes toward one side of the rotor to abut against and limit the rotor.

[0017] The utility model also provides a vehicle, comprising the range extender mentioned above.

[0018] Compared with the prior art, in the technical solution of the utility model, the range extender includes an engine, which is provided with a crankshaft for power output; the range extender also includes a generator, which has a casing and a stator and a rotor arranged in the casing, the rotor is connected to the crankshaft and rotates under the drive of the crankshaft to generate electricity; in addition, in the present solution, the casing includes two parts: a shell and an end plate, wherein the interior of the shell forms a receiving cavity with openings at both ends, the stator and the rotor are arranged in the receiving cavity, the end plate is arranged at one side opening of the receiving cavity, and the end plate is integrally formed with the shell, so that, compared with the traditional structure in which the shell and the end plate are connected by screw connection or the like, the present solution can simplify the connection structure between the end plate and the shell, which is conducive to reducing the number of parts of the range extender and reducing the production cost, and at the same time, it can also make the range extender smaller in axial size and easier to arrange, in addition, the integrated design of the end plate and the shell also improves the overall strength of the casing, thereby improving the overall strength of the range extender. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0020] Figure 1 The present invention is a schematic cross-sectional view of an embodiment of a range extender provided by the present invention.

[0021] Description of Figure Numbers:

[0022] 10. crankshaft; 100. casing; 110. housing; 120. end plate; 200. stator; 300. rotor; 400. junction box; 500. front cover; 600. bearing; 700. resolver; 800. sealing cover.

[0023] The realization of the purpose, functional features and advantages of the utility model will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0025] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0026] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the utility model, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the utility model.

[0027] In order to reduce the overall size and number of parts of the range extender and improve the overall structural strength of the range extender, the present technical solution proposes a range extender, comprising:

[0028] an engine having a crankshaft 10; and

[0029] The generator includes a casing 100, a stator 200 and a rotor 300 arranged inside the casing 100, the rotor 300 is connected to the crankshaft 10, the casing 100 includes a shell 110 and an end plate 120, the interior of the shell 110 forms a receiving cavity with openings at both ends, the stator 200 and the rotor 300 are arranged in the receiving cavity, and the end plate 120 is arranged at an opening and is integrally formed with the shell 110.

[0030] Compared with the prior art, in the technical solution of the utility model, the range extender includes an engine, which is provided with a crankshaft 10 for power output; the range extender also includes a generator, which has a housing 100 and a stator 200 and a rotor 300 arranged in the housing 100, and the rotor 300 is connected to the crankshaft 10 and rotates under the drive of the crankshaft 10 to generate electricity; in addition, in the present solution, the housing 100 includes two parts, a shell 110 and an end plate 120, wherein the interior of the shell 110 forms a receiving cavity with two ends opening, and the stator 200 and the rotor 300 are arranged in the receiving cavity Inside, the end plate 120 is arranged at an opening on one side of the accommodating cavity, and the end plate 120 is integrally formed with the shell 110. In this way, compared with the traditional structure in which the shell 110 and the end plate 120 are connected by screw connection or the like, this solution can simplify the connection structure between the end plate 120 and the shell 110, which is beneficial to reduce the number of parts of the range extender and reduce production costs. At the same time, it can also make the axial size of the range extender smaller and easier to arrange. In addition, the integrated design of the end plate 120 and the shell 110 also improves the overall strength of the casing 100, thereby improving the overall strength of the range extender.

[0031] like Figure 1In one embodiment of the utility model, the range extender has an engine, which is provided with a housing and a crankshaft 10 rotatably arranged on the housing, the crankshaft 10 is used to output power to the outside, and the range extender also includes a generator, the generator has a housing 100 and a rotor 300 and a stator 200 arranged in the housing 100, the rotor 300 is connected to the crankshaft 10 and rotates under the drive of the crankshaft 10, and electric energy is generated and transmitted to the outside through the cooperation of the rotor 300 and the stator 200; in this scheme, the housing 100 is connected to the housing so that the generator is installed on the engine as a whole, and the housing 100 includes two parts, a shell 110 and an end plate 120, the shell 110 is cylindrical, and the shell 110 has a receiving cavity with two ends opened, the stator 200 and the rotor 300 are arranged in the receiving cavity, and in addition, the end plate 120 is arranged at one side opening of the receiving cavity The opening is closed to protect the stator 200 and the rotor 300 inside. During assembly, the stator 200 and the rotor 300 can be installed into the accommodating cavity from the opening on the other side of the accommodating cavity. Then, the periphery of the opening on this side can cooperate with the outer casing of the engine to close the accommodating cavity, isolate the rotor 300 and the stator 200 from the outside, and ensure the reliability of operation. In addition, in order to reduce the structural complexity of the generator, the shell 110 and the end plate 120 in the present solution can be integrally formed, which can simplify the connection structure between the end plate 120 and the shell 110, reduce the number of parts of the engine, and reduce the difficulty of assembling the range extender. At the same time, it can also make the range extender smaller in axial size, which is more convenient to arrange on the vehicle body. The integrated design reduces the number of sealing surfaces of the generator shell 100, has better sealing, and has higher strength of the generator shell 100.

[0032] like Figure 1 In one embodiment of the utility model, the range extender further includes:

[0033] The junction box 400 is disposed on the side of the housing 110 and communicates with the accommodating cavity;

[0034] The connection terminal is disposed in the connection box 400 and is conductively connected to the stator 200 .

[0035] In this embodiment, in order to further improve the integration of the range extender, a junction box 400 is further provided on the side of the housing 110 of the generator. The junction box 400 is connected to the accommodating cavity, and the wiring harness of the generator can be inserted into the junction box 400. In addition, a series of wiring terminals are provided in the junction box 400, and the wiring terminals are used to connect the wiring harness of the generator with the external circuit. The setting of the junction box 400 can provide protection for the wiring terminals and the wiring harness of the generator, thereby ensuring the adaptability and durability of the generator in complex environments; and for the convenience of maintenance and assembly, the junction box 400 can be provided with a quick-release box cover, so that technicians can quickly check or replace the electrical connection without disassembling the entire generator; in addition, it can be imagined that in order to further simplify the structure and improve the integration, the wiring harness of the engine can also be inserted into the junction box 400 and connected to the outside through the wiring terminals in the junction box 400, which is more convenient for the electrical inspection and maintenance of the entire range extender and simplifies the electrical maintenance work.

[0036] In an embodiment of the utility model, the junction box 400 is integrally formed with the housing 110, and the junction box 400 is integrated with the housing 110 by using metal processing technology such as casting, so that not only the joint gap between the junction box 400 and the housing 110 is removed, but also the stability and sealing performance of the overall structure are greatly improved. At the same time, the number of parts is reduced, the production process is simplified, the assembly cost is reduced, and the dust and water resistance of the generator is enhanced, and the reliability and durability of long-term use are improved.

[0037] like Figure 1In one embodiment of the utility model, the range extender further includes a front cover 500, which is disposed at another opening and is detachably connected to the housing 110, and the housing 110 is connected to the engine through the front cover 500; in this embodiment, the front cover 500 is disposed at the edge of another opening of the generator housing 100, and is detachably connected to the housing 110. The front cover 500 not only seals the accommodating cavity to provide protection for the stator 200 and the rotor 300 inside, but also serves as a bridge connecting the housing 110 and the engine. In addition, the provision of the front cover 500 makes it unnecessary to provide an adaptive connection structure on the end face where the engine and the generator are connected, thereby simplifying the design of the engine. In this solution, the detachable connection between the front cover 500 and the housing 110 can be bolt fixing, snap-on design, or quick-release lock, etc., thereby ensuring the firmness of the connection and the ease of disassembly and assembly. In terms of materials, the front cover 500 can be made of materials with certain strength and weather resistance, such as engineering plastics or lightweight alloys, which not only ensures sufficient protection but also takes into account the need for lightweight; the front cover 500 and the engine housing can also be connected in the above-mentioned manner. In addition, a sealing structure such as a sealing ring can be set between the front cover 500 and the housing 110 to ensure the sealing of the accommodating cavity. In addition, a vibration reduction structure can be set between the front cover 500 and the engine housing to reduce the vibration transmitted to the engine, thereby improving the reliability of the generator. The vibration reduction mechanism can be a vibration isolation layer constructed of multiple layers of vibration isolation materials (such as rubber pads, springs and damping composite materials). In addition, a tuned mass damper and other devices can also be separately set on the generator housing 100 to reduce the vibration of the generator, thereby reducing the noise and vibration generated during the operation of the generator, improving the reliability of the range extender and enhancing the user experience.

[0038] like Figure 1 In one embodiment of the utility model, the rotor 300 is directly connected to the crankshaft 10. In order to further improve the compactness and efficiency of the range extender, in this embodiment, the rotor 300 and the crankshaft 10 can be directly connected, and the power of the crankshaft 10 can be directly transmitted to the rotor 300 shaft. By directly connecting the rotor 300 to the crankshaft 10, the traditional indirect transmission method is abandoned, which not only improves the efficiency of power transmission, reduces the energy loss caused by the intermediate links, but also reduces the complexity and maintenance cost of the system. Without the wear and noise of additional transmission parts, the entire range extender runs more smoothly. In addition, this design also helps to reduce the size of the whole machine and optimize the space layout.

[0039] In one embodiment of the utility model, a first flange is convexly provided at one end of the crankshaft 10, and a second flange is convexly provided at one end of the rotor 300. The first flange and the second flange are connected by screw locking. Specifically, the first flange can be processed on one end of the crankshaft 10 by an integral molding method, and the second flange can also be processed on the rotor 300 shaft of the rotor 300 by an integral molding method. A plurality of first connection holes can be arranged at equal intervals around the rotation axis of the crankshaft 10 on the first flange, and a plurality of second connection holes corresponding to the positions of the first connection holes can be arranged on the second flange. The first connection hole and the second connection hole can be fixed by screw locking. The method of locking and fixing the first flange and the second flange by screws not only ensures a firm connection between the two components and prevents loosening under high speed or high torque conditions, but also allows for convenient disassembly and reassembly when necessary, which is convenient for maintenance and adjustment. The selection of the screw locking method also means that the tightness of the connection can be controlled according to actual work requirements, further improving the reliability and adaptability of the connection. Through this flange and screw locking connection solution, direct power transmission between the rotor 300 and the crankshaft 10 is achieved, the complexity of the connection structure is reduced, and the power transmission efficiency and operation stability of the entire range extender are improved.

[0040] In one embodiment of the utility model, the end plate 120 is provided with a support hole, the support hole is communicated with the accommodating cavity, and one end of the rotor 300 is rotatably connected to the support hole. By providing the support hole to provide support for the rotor 300, both ends of the rotor 300 have sufficient support when rotating, which helps to reduce the load of the end of the rotor 300 directly connected to the crankshaft 10, while ensuring the radial and axial stability of the rotor 300 during rotation, reducing vibration and noise, and improving the smoothness of the overall operation.

[0041] like Figure 1 In one embodiment of the utility model, the range extender further includes a bearing 600, which is disposed in the support hole. The rotor 300 is rotatably connected to the end plate 120 via the bearing 600. The bearing 600 may be a deep groove ball bearing 600, which has an inner ring and an outer ring. The rotor 300 is interference-connected with the inner ring of the bearing 600, and the outer ring of the bearing 600 is interference-mounted in the support hole. The arrangement of the bearing 600 can ensure the stability of the rotor 300 during rotation and reduce friction loss. Figure 1In another embodiment of the utility model, the range extender further comprises a resolver 700, which is arranged in the support hole and connected to the rotor 300. The resolver 700 is installed inside the support hole and connected to the rotor 300. In this way, the resolver 700 monitors and feeds back the speed and position information of the rotor 300 in real time, ensuring the dynamic responsiveness and efficiency of the motor drive and improving the accuracy of the range extender control. In addition, the bearing 600 and the resolver 700 in the above scheme can both be arranged in the support hole, so that the space utilization can be maximized, so that the range extender integrates more functional components in a limited space, further improving the integration of the range extender. In order to further improve the integration of the range extender, the outer peripheral wall of the generator can be hollowed to form a flow channel for the flow of coolant. In addition, a liquid inlet and a liquid outlet connected to the flow channel can be arranged on the generator, and the coolant can enter the flow channel to cool the generator, thereby improving the working efficiency of the generator. The integration of the cooling function on the generator also improves the integration of the range extender.

[0042] like Figure 1 In one embodiment of the utility model, the range extender further includes a sealing cover 800, which is disposed on the side of the support hole away from the rotor 300, and the sealing cover 800 is sealed and connected to the support hole. The sealing cover 800 is connected to the periphery of the support hole by a detachable connection such as screw connection, and the sealing cover 800 can be sealed with the inner wall of the support hole through a sealing ring, so that dust and moisture in the external environment can be effectively isolated, and the internal components such as the bearing 600 and the resolver 700 are protected from pollution and corrosion, and the internal lubricating oil or grease is ensured not to leak, and the long-term lubrication and cooling of the bearing 600 is maintained, thereby extending the service life of the range extender and reducing the maintenance requirements. In another embodiment of the utility model, the periphery of the support hole protrudes toward one side of the rotor 300 to abut against the rotor 300 and limit the rotor 300. This design positions and supports the rotor 300 axially when it rotates, thereby preventing the rotor 300 from axially moving, further enhancing the stability of the rotor 300 , reducing vibration during operation, and improving the smoothness and efficiency of the motor operation.

[0043] The utility model also proposes a vehicle, which includes a vehicle body and a range extender arranged on the vehicle body. The specific structure of the range extender refers to the above-mentioned embodiment. Since the vehicle adopts all the technical solutions of all the above-mentioned embodiments, it at least has all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be repeated here one by one.

[0044] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A range extender, characterized in that: The range extender comprises: an engine having a crankshaft; and A generator, the generator includes a casing, a stator and a rotor arranged inside the casing, the rotor is connected to the crankshaft, the casing includes a shell and an end plate, the shell has an interior forming a receiving cavity with openings at both ends, the stator and the rotor are arranged in the receiving cavity, the end plate is arranged at one of the openings and is integrally formed with the shell.

2. The range extender according to claim 1, characterized in that: The range extender also includes: A junction box, disposed on a side of the housing and connected to the accommodating cavity; The connection terminal is arranged in the connection box and is conductively connected to the stator.

3. The range extender according to claim 2, characterized in that: The junction box and the housing are integrally formed.

4. The range extender according to claim 1, characterized in that: The range extender further includes a front cover, which is disposed at another of the openings and is detachably connected to the housing, and the housing is connected to the engine through the front cover.

5. The range extender according to claim 1, characterized in that: The rotor is directly connected to the crankshaft.

6. The range extender according to claim 5, characterized in that: A first flange is protrudingly provided at one end of the crankshaft, and a second flange is protrudingly provided at one end of the rotor. The first flange and the second flange are connected by screw locking.

7. The range extender according to claim 5, characterized in that: The end plate is provided with a supporting hole, the supporting hole is communicated with the accommodating cavity, and one end of the rotor is rotatably connected to the supporting hole.

8. The range extender according to claim 7, characterized in that: The range extender further includes a bearing, which is disposed in the support hole, and the rotor is rotatably connected to the end plate via the bearing; and / or the range extender further includes a resolver, which is disposed in the support hole and connected to the rotor.

9. The range extender according to claim 8, characterized in that: The range extender also includes a sealing cover, which is arranged on a side of the support hole away from the rotor, and the sealing cover is sealed and connected to the support hole; and / or the periphery of the support hole protrudes toward one side of the rotor to abut against the rotor and limit the rotor.

10. A vehicle, characterized in that: A range extender comprising the range extender as described in any one of claims 1 to 9.

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