Range extender generator and engine connecting structure and range extender

Abstract

The utility model provides a connecting structure of a range extender generator and an engine and the range extender, and belongs to the technical field of automobile parts, the connecting structure of the range extender generator and the engine comprises a crankshaft flange, a first end plate, a motor rotor and a second end plate which are sequentially arranged along the axial direction; wherein the first end plate and the second end plate are respectively connected to the motor rotor, and the crankshaft flange is respectively connected to the first end plate and an engine cylinder body. The utility model provides a range extender generator and engine connecting structure and a range extender, and aims to solve the problems that a range extender motor in the prior art is complex in structure, large in overall size and weight, unstable in generator performance, low in installation efficiency and high in cost.

Description

Technical Field

[0001] The utility model belongs to the technical field of automobile parts, and more specifically, relates to a range extender generator and engine connection structure and a range extender. Background Art

[0002] At present, extended-range electric vehicles have become the mainstream of new energy vehicles, with great advantages in cost-effectiveness and vehicle availability. The range extender is an additional energy storage component installed on electric vehicles. It has the function of automatic charging of electric vehicles and can increase the range of electric vehicles. It is the core component of extended-range electric vehicles.

[0003] The range extender is mainly composed of an engine, a generator and a connection structure. At present, in addition to the connection between the engine and the generator output shaft, the range extender used in the range extender of the extended-range electric vehicle also has a drive motor that is physically connected to the range extender through the shell. This structure effectively improves the integration. The working principle of the range extender generator and engine connection structure is to use the engine to convert the chemical energy in gasoline or diesel into mechanical energy, and use the generator to convert mechanical energy into electrical energy. This part of the electrical energy is mainly used to drive the motor and charge the electric vehicle battery, thereby further increasing the range of the electric vehicle.

[0004] The generator is bolted to the engine through the rotor bracket, and the generator rotor core is installed on the motor rotor bracket. It is positioned circumferentially through key slots and key insertions, and axially through retaining rings or pressure rings. After long-term use, there is a risk that the retaining ring will loosen, causing the rotor to move axially, affecting the performance of the generator. In addition, the assembly of the generator with a rotor bracket is relatively time-consuming. The rotor core must be installed on the rotor bracket first, and then the rotor bracket must be installed on the shaft. The operation is relatively complicated, and the installation of the rotor bracket increases the cost. Utility Model Content

[0005] The purpose of the utility model is to provide a range extender generator and engine connection structure and a range extender, aiming to solve the problems in the prior art that the range extender motor has a complex structure, a large overall volume and weight, resulting in unstable generator performance, low installation efficiency and high cost.

[0006] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0007] In a first aspect, a range extender generator and engine connection structure is provided, comprising a crankshaft flange, a first end plate, a motor rotor and a second end plate arranged in sequence along the axial direction; wherein the first end plate and the second end plate are respectively connected to the motor rotor, and the crankshaft flange is respectively connected to the first end plate and the engine cylinder block.

[0008] In combination with the first aspect, in a possible implementation, the first end plate and the second end plate both include a limiting portion and a fixing portion sleeved outside the limiting portion, the limiting portion is inserted into the center hole of the motor rotor, and the fixing portion is connected to the motor rotor.

[0009] In combination with the first aspect, in a possible implementation, a positioning groove is provided on the end face of the crankshaft flange, one end of the limiting portion of the first end plate is inserted into the center hole of the motor rotor, and the other end is inserted into the positioning groove, and the fixing portion is axially abutted against the motor rotor and the crankshaft flange respectively.

[0010] In combination with the first aspect, in a possible implementation, the first end plate is provided with a first positioning hole, the crankshaft flange is provided with a second positioning hole corresponding to the first positioning hole, and positioning pieces are inserted into the first positioning hole and the second positioning hole.

[0011] In combination with the first aspect, in a possible implementation, the crankshaft flange, the first end plate, the motor rotor and the second end plate are respectively provided with corresponding locking holes, and locking pieces are inserted into the locking holes. The locking pieces connect the crankshaft flange, the first end plate, the motor rotor and the second end plate in sequence.

[0012] The beneficial effect of the range extender generator and engine connection structure provided by the utility model is that: compared with the prior art, the range extender generator and engine connection structure of the utility model is connected to the motor rotor through the first end plate and the second end plate respectively, and the motor rotor is fixed in the circumferential direction and the axial direction respectively. The crankshaft flange is connected to the engine cylinder block and the first end plate respectively to achieve the connection between the motor rotor and the engine cylinder block. The solution in the utility model does not need to use a motor bracket to install the motor rotor, and at the same time simplifies the solution of the axial positioning of the motor rotor by a retaining ring or a pressure ring, which not only reduces the connection and installation components of the motor rotor, saves installation and manufacturing costs, but also makes the overall structure of the motor rotor more compact after installation, ensuring the stable performance of the generator. In addition, the first end plate is arranged between the crankshaft flange and the motor rotor, which can avoid the problem of shortening the magnetic conduction path between the rotor and the crankshaft due to the omission of the rotor bracket, thereby causing the crankshaft to be magnetized.

[0013] In the second aspect, an embodiment of the utility model further provides a range extender, comprising the range extender generator and engine connection structure described in any one of the above items, and a motor stator mounted outside the motor rotor and a resolver motor connected to the second end plate, and also comprising an engine block and a motor housing connected to the engine block, the motor housing and the engine block enclose a containing chamber, and the crankshaft flange, the first end plate, the motor rotor, the second end plate, the resolver motor and the motor stator are all arranged in the containing chamber.

[0014] In combination with the second aspect, in a possible implementation, the second end plate has a connection portion extending toward an end away from the motor rotor, and the resolver motor is sleeved outside the connection portion.

[0015] In combination with the second aspect, in a possible implementation, a fixing groove is provided on the outer circumferential surface of the connecting portion, and the fixing groove is connected to the outside in a direction away from the motor rotor. The rotary transformer motor is inserted into the fixing groove and abuts against the connecting portion along the axial direction.

[0016] In combination with the second aspect, in a possible implementation, the motor housing has a limiting groove, the resolver motor is axially inserted into the limiting groove and axially abuts against the motor housing.

[0017] In combination with the second aspect, in a possible implementation, the engine cylinder block is provided with a receiving groove, and the crankshaft flange has a receiving portion inserted into the receiving groove.

[0018] The beneficial effect of the range extender provided by the utility model is that: compared with the prior art, the above-mentioned range extender generator and engine connection structure is adopted, and the first end plate and the second end plate are respectively connected to the motor rotor, so as to fix the motor rotor in the circumferential direction and the axial direction respectively. The crankshaft flange is respectively connected to the engine cylinder block and the first end plate to realize the connection between the motor rotor and the engine cylinder block. The solution in the utility model does not need to use a motor bracket to install the motor rotor, and at the same time simplifies the solution of the axial positioning of the motor rotor by a retaining ring or a pressure ring, which not only reduces the connection and installation components of the motor rotor, saves installation and manufacturing costs, but also makes the overall structure of the motor rotor more compact after installation, ensuring the stable performance of the generator. In addition, the first end plate is arranged between the crankshaft flange and the motor rotor, which can avoid the problem of the magnetization of the crankshaft caused by the omission of the rotor bracket, which causes the magnetic conduction path between the rotor and the crankshaft to become shorter. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, 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 present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0020] Figure 1 A schematic diagram of the structure of the range extender generator and the engine connection structure provided by an embodiment of the utility model;

[0021] Figure 2 A cross-sectional view of the connection structure between the range extender generator and the engine provided in an embodiment of the utility model;

[0022] Figure 3 A schematic diagram of the structure of the engine cylinder block and crankshaft flange used in the embodiment of the utility model;

[0023] Figure 4 A schematic diagram of the structure of the first end plate used in an embodiment of the utility model;

[0024] Figure 5 A cross-sectional view of a first end plate used in an embodiment of the present utility model;

[0025] Figure 6 A cross-sectional view of a second end plate used in an embodiment of the present utility model;

[0026] Figure 7 A cross-sectional view of a range extender provided in an embodiment of the utility model.

[0027] In the figure: 1. engine block; 2. crankshaft flange; 201. locking hole; 202. second positioning hole; 203. positioning groove; 3. first end plate; 301. limiting part; 302. fixing part; 303. first positioning hole; 4. motor rotor; 401. rotor core; 5. second end plate; 501. fixing groove; 502. connecting part; 6. locking member; 7. positioning member; 8. resolver motor; 801. resolver rotor; 802. resolver stator; 9. motor stator; 10. motor housing. DETAILED DESCRIPTION

[0028] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0029] In the claims, specification and the above drawings of the present utility model, unless otherwise clearly defined, the terms "first", "second" or "third" are used to distinguish different objects, rather than to describe a specific order. Unless otherwise specified, other directional words, such as "vertical", "clockwise", "counterclockwise", etc., indicating directions or positional relationships are based on the directions and positional relationships shown in the drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction or be constructed and operated in a specific direction, so it cannot be understood as limiting the specific protection scope of the present utility model. In the claims, specification and the above drawings of the present utility model, unless otherwise clearly defined, the terms "fixed connection" or "fixed connection" should be understood in a broad sense, that is, any connection method without a displacement relationship and relative rotation relationship between the two, that is, including non-detachable fixed connection, detachable fixed connection, integrated connection and fixed connection through other devices or elements. In the claims, specification and the above drawings of the present utility model, the terms "including", "having" and their variations are used, and the intention is to "include but not limited to".

[0030] Please also read Figures 1 to 6 The range extender generator and engine connection structure and the range extender provided by the utility model are now described. The range extender generator and engine connection structure comprises a crankshaft flange 2, a first end plate 3, a motor rotor 4 and a second end plate 5 arranged in sequence along the axial direction; wherein the first end plate 3 and the second end plate 5 are respectively connected to the motor rotor 4, and the crankshaft flange 2 is respectively connected to the first end plate 3 and the engine cylinder block 1.

[0031] Compared with the prior art, the range extender generator and engine connection structure provided by the utility model is respectively connected to the motor rotor 4 through the first end plate 3 and the second end plate 5, respectively, to achieve the fixation of the motor rotor 4 in the circumferential direction and the axial direction. The crankshaft flange 2 is respectively connected to the engine cylinder block 1 and the first end plate 3 to achieve the connection between the motor rotor 4 and the engine cylinder block 1. The solution in the utility model does not need to use a motor bracket to install the motor rotor 4, and at the same time simplifies the solution of the axial positioning of the motor rotor 4 by the clamping ring or the pressure ring, which not only reduces the connection and installation components of the motor rotor 4, saves the installation and manufacturing costs, but also makes the overall structure of the motor rotor 4 more compact after installation, ensuring the stable performance of the generator. In addition, the first end plate 3 is arranged between the crankshaft flange 2 and the motor rotor 4, which can avoid the problem of shortening the magnetic conduction path between the rotor and the crankshaft due to the omission of the rotor bracket, thereby causing the crankshaft to be magnetized.

[0032] Specifically, the first end plate 3 and the second end plate 5 are both designed with non-magnetic steel (non-magnetic steel), which can effectively avoid the problem that the rotor is miniaturized due to the adoption of the solution in the present application, resulting in a shortened magnetic path between the rotor and the crankshaft, and then causing the first end plate 3 and the crankshaft flange 2 to be magnetized, resulting in the rotor being adsorbed on the crankshaft flange 2, or the crankshaft flange 2 being magnetized so that the engine crankshaft adsorbs metal particles, causing the engine to fail.

[0033] It should be noted that the motor rotor 4 includes a plurality of rotor cores 401 arranged in sequence along the axial direction. If the rotor core 401 adopts a multi-section skew pole design, the rotor core 401 should be processed by integral injection molding to ensure the connection strength of the multi-section cores themselves.

[0034] In some embodiments, see Figures 4 to 6 The first end plate 3 and the second end plate 5 both include a limiting portion 301 and a fixing portion 302 sleeved outside the limiting portion 301 , the limiting portion 301 is inserted into the central hole of the motor rotor 4 , and the fixing portion 302 is connected to the motor rotor 4 .

[0035] The limiting portion 301 is inserted into the central hole of the motor rotor 4 to position the motor rotor 4 in the radial direction, and the fixing portion 302 abuts against the motor rotor 4 and is fixed to the motor rotor 4, that is, the first end plate 3 and the second end plate 5 apply an extrusion force to the motor rotor 4 in the axial direction to achieve axial fixation of the motor rotor 4. The scheme in this embodiment increases the contact area between the first end plate 3 and the second end plate 5 and the motor rotor 4, respectively limits the motor rotor 4 in the radial direction and the axial direction, and at the same time, the motor rotor 4 is fixed circumferentially under the action of the extrusion force, thereby improving the stability of the motor rotor 4 after being fixed.

[0036] Optionally, the limiting portion 301 is interference fit with the center hole of the motor rotor 4 to achieve radial and circumferential limiting.

[0037] Optionally, the fixing portion 302 is detachably connected to the motor rotor 4 , for example, by snapping or screwing.

[0038] In some embodiments, see Figure 3 A positioning groove 203 is provided on the end surface of the crankshaft flange 2, one end of the limiting portion 301 of the first end plate 3 is inserted into the center hole of the motor rotor 4, and the other end is inserted into the positioning groove 203, and the fixing portion 302 is axially abutted against the motor rotor 4 and the crankshaft flange 2 respectively.

[0039] The limiting portion 301 is inserted into the positioning groove 203 of the crankshaft flange 2, which can not only realize radial positioning, but also align the centers of the first end plate 3 and the crankshaft flange 2. The fixing portion 302 abuts against the end surface of the crankshaft flange 2, thereby realizing axial positioning of the crankshaft flange 2 and the first end plate 3, and improving the firmness of the connection between the first end plate 3 and the crankshaft flange 2. In addition, the solution in this embodiment makes the connection between the crankshaft flange 2, the first end plate 3 and the motor rotor 4 more compact, reducing the overall volume.

[0040] Specifically, the center hole of the crankshaft flange 2 forms a positioning groove 203 .

[0041] In some embodiments, see Figure 2 and Figure 4 The first end plate 3 is provided with a first positioning hole 303 , the crankshaft flange 2 is provided with a second positioning hole 202 corresponding to the first positioning hole 303 , and positioning members 7 are inserted into the first positioning hole 303 and the second positioning hole 202 .

[0042] The positioning member 7 is first inserted into the first positioning hole 303 and then inserted into the second positioning hole 202, which not only realizes the pre-installation of the first end plate 3 and the crankshaft flange 2, but also realizes the positioning function without alignment, thereby improving the installation efficiency. Of course, the positioning member 7 can also be first inserted into the second positioning hole 202 and then inserted into the first positioning hole 303.

[0043] In some embodiments, see Figure 2 The crankshaft flange 2, the first end plate 3, the motor rotor 4 and the second end plate 5 are respectively provided with corresponding locking holes 201, and a locking piece 6 is inserted into the locking hole 201. The locking piece 6 connects the crankshaft flange 2, the first end plate 3, the motor rotor 4 and the second end plate 5 in sequence.

[0044] The locking member 6 can support and fix the motor rotor 4, and there is no need to install bearings for support, which simplifies the connection structure. In addition, the locking member 6 is inserted into the plurality of locking holes 201 in sequence, and the crankshaft flange 2, the first end plate 3, the motor rotor 4 and the second end plate 5 are integrally connected. Compared with the solution of connecting one by one, the installation accuracy is higher and the installation deviation is reduced.

[0045] Optionally, the engine crankshaft is made of forged steel to improve the overall modality.

[0046] Optionally, the locking member 6 is a threaded member or a clamping member.

[0047] Optionally, the locking hole 201 on the second end plate 5 is a countersunk hole, and the end portion of the locking member 6 is located in the countersunk hole to avoid interference with other external components.

[0048] Optionally, the crankshaft flange 2 is provided with a plurality of locking holes 201, and the centers of the plurality of locking holes 201 are located on the same circumferential surface; the first end plate 3, the motor rotor 4 and the second end plate 5 are provided with corresponding locking holes 201, thereby increasing the connection points and improving the firmness of the connection.

[0049] Optionally, the positioning hole and the locking hole 201 are located on the same circumferential surface.

[0050] Based on the same inventive concept, the utility model also provides a range extender. Figure 7 The range extender includes any one of the above-mentioned range extender generator and engine connection structures, as well as a motor stator 9 sleeved outside the motor rotor 4, and a resolver motor 8 connected to the second end plate 5. It also includes an engine cylinder block 1 and a motor housing 10 connected to the engine cylinder block 1. The motor housing 10 and the engine cylinder block 1 are enclosed to form a accommodating chamber, and the crankshaft flange 2, the first end plate 3, the motor rotor 4, the second end plate 5, the resolver motor 8 and the motor stator 9 are all arranged in the accommodating chamber.

[0051] The range extender provided by the utility model adopts the above-mentioned range extender generator and engine connection structure, and is connected to the motor rotor 4 through the first end plate 3 and the second end plate 5, respectively, to achieve the fixation of the motor rotor 4 in the circumferential direction and the axial direction. The crankshaft flange 2 is respectively connected to the engine cylinder body 1 and the first end plate 3 to achieve the connection between the motor rotor 4 and the engine cylinder body 1. The solution in the utility model does not need to use a motor bracket to install the motor rotor 4, and at the same time simplifies the solution of the axial positioning of the motor rotor 4 by the retaining ring or the pressure ring, which not only reduces the connection and installation components of the motor rotor 4, saves the installation and manufacturing costs, but also makes the overall structure of the motor rotor 4 more compact after installation, ensuring the stable performance of the generator. In addition, the first end plate 3 is arranged between the crankshaft flange 2 and the motor rotor 4, which can avoid the problem of the magnetization of the crankshaft caused by the omission of the rotor bracket, which causes the magnetic conduction path between the rotor and the crankshaft to become shorter.

[0052] In some embodiments, see Figure 7 The second end plate 5 has a connecting portion 502 extending toward one end away from the motor rotor 4 , and the resolver motor 8 is sleeved outside the connecting portion 502 .

[0053] The resolver motor 8 is sleeved outside the connection portion 502 to achieve concentric connection between the resolver motor 8 and the motor rotor 4. There is no need to align and position the resolver motor 8, and radial limitation of the resolver motor 8 is achieved.

[0054] It should be noted that the resolver motor 8 includes a resolver rotor 801 sleeved outside the connecting portion 502 and a resolver stator 802 sleeved outside the resolver rotor 801 .

[0055] In some embodiments, see Figure 6 and Figure 7A fixing groove 501 is formed on the outer circumferential surface of the connecting portion 502 . The fixing groove 501 is connected to the outside in a direction away from the motor rotor 4 . The resolver motor 8 is inserted into the fixing groove 501 and abuts against the connecting portion 502 in the axial direction.

[0056] The resolver motor 8 is inserted into the fixing groove 501, which not only realizes the concentric connection between the resolver motor 8 and the motor rotor 4, but also the resolver motor 8 abuts against the end surface of the fixing groove 501 to realize axial limitation. This embodiment adopts the abutment method to position the resolver motor 8 in the axial direction, reduces the use of external connectors, and simplifies the connection structure.

[0057] Optionally, the other end of the resolver motor 8 abuts against the motor housing 10 .

[0058] In some embodiments, see Figure 7 The motor housing 10 has a limiting groove, and the resolver motor 8 is inserted into the limiting groove along the axial direction and abuts against the motor housing 10 along the axial direction.

[0059] In this embodiment, the motor housing 10 and the connecting portion 502 abut against two ends of the resolver motor 8 respectively, and position the resolver motor 8 in the axial direction to ensure the stability of the position of the resolver motor 8 .

[0060] Optionally, the resolver stator 802 of the resolver motor 8 is interference-fitted in the limiting groove, and the resolver stator 802 can be fixed without using external connecting parts.

[0061] In some embodiments, see Figure 2 and Figure 7 The engine cylinder block 1 is provided with a receiving groove, and the crankshaft flange 2 has a receiving portion inserted into the receiving groove.

[0062] After the motor housing 10 is connected to the engine block 1, the crankshaft flange 2, the first end plate 3, the motor rotor 4, the second end plate 5 and the resolver motor 8 are positioned in the axial direction, and the crankshaft flange 2 is inserted into the receiving groove to achieve radial positioning of the crankshaft flange 2. Since the crankshaft flange 2 is also connected to the first end plate 3, the crankshaft flange 2 is fixed. In this embodiment, the crankshaft flange 2 can be fixed to the engine block 1 without using an external connector, which simplifies the connection structure and installation steps.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. The range extender generator and engine connection structure is characterized by: The invention comprises a crankshaft flange (2), a first end plate (3), a motor rotor (4) and a second end plate (5) which are arranged in sequence along the axial direction; wherein the first end plate (3) and the second end plate (5) are respectively connected to the motor rotor (4), and the crankshaft flange (2) is respectively connected to the first end plate (3) and the engine cylinder block (1).

2. The range extender generator and engine connection structure according to claim 1, characterized in that: The first end plate (3) and the second end plate (5) both comprise a limiting portion (301) and a fixing portion (302) sleeved outside the limiting portion (301); the limiting portion (301) is inserted into a central hole of the motor rotor (4); and the fixing portion (302) is connected to the motor rotor (4).

3. The range extender generator and engine connection structure according to claim 2, characterized in that: A positioning groove (203) is provided on the end surface of the crankshaft flange (2); one end of the limiting portion (301) of the first end plate (3) is inserted into the central hole of the motor rotor (4), and the other end is inserted into the positioning groove (203); and the fixing portion (302) abuts against the motor rotor (4) and the crankshaft flange (2) along the axial direction.

4. The range extender generator and engine connection structure according to claim 1, characterized in that: The first end plate (3) is provided with a first positioning hole (303), the crankshaft flange (2) is provided with a second positioning hole (202) corresponding to the first positioning hole (303), and positioning pieces (7) are inserted into the first positioning hole (303) and the second positioning hole (202).

5. The range extender generator and engine connection structure according to claim 1, characterized in that: The first end plate (3), the motor rotor (4) and the second end plate (5) are respectively provided with corresponding locking holes (201), and a locking member (6) is inserted into the locking hole (201), and the locking member (6) connects the crankshaft flange (2), the first end plate (3), the motor rotor (4) and the second end plate (5) in sequence.

6. A range extender, characterized in that: A range extender generator and engine connection structure as described in any one of claims 1 to 5, as well as a motor stator (9) sleeved outside the motor rotor (4), and a resolver motor (8) connected to the second end plate (5), and also includes an engine cylinder block (1) and a motor housing (10) connected to the engine cylinder block (1), the motor housing (10) and the engine cylinder block (1) enclose a containing chamber, and the crankshaft flange (2), the first end plate (3), the motor rotor (4), the second end plate (5), the resolver motor (8) and the motor stator (9) are all arranged in the containing chamber.

7. The range extender according to claim 6, characterized in that: The second end plate (5) has a connecting portion (502) extending toward an end away from the motor rotor (4), and the resolver motor (8) is sleeved outside the connecting portion (502).

8. The range extender according to claim 7, characterized in that: The outer peripheral surface of the connecting portion (502) is provided with a fixing groove (501), and the fixing groove (501) is connected to the outside in a direction away from the motor rotor (4). The rotary motor (8) is inserted into the fixing groove (501) and abuts against the connecting portion (502) in the axial direction.

9. The range extender according to claim 6, characterized in that: The motor housing (10) has a limiting groove, and the resolver motor (8) is inserted into the limiting groove along the axial direction and abuts against the motor housing (10) along the axial direction.

10. The range extender according to claim 6, characterized in that: The engine cylinder block (1) is provided with a receiving groove, and the crankshaft flange (2) has a receiving portion inserted into the receiving groove.

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