Range extender

Abstract

The utility model provides a range extender which comprises an input shaft, a speed increasing planet row, a generator and a cooling mechanism, the input shaft is connected with an engine, the input shaft is connected with a planet carrier of the speed increasing planet row, and a sun gear of the speed increasing planet row is connected with a motor shaft of the generator; the cooling mechanism comprises a heat exchanger, an electronic pump, a suction filter and an oil duct, the electronic pump is used for sucking oil from the suction filter and feeding the oil into the heat exchanger, cooling liquid in the heat exchanger cools the oil, and the cooled oil enters the oil duct. According to the range extender provided by the utility model, the overall structure of the range extender is optimized, the overall space and weight of the range extender are reduced, the speed-increasing planet row which is coaxially arranged is arranged, the occupation of the arrangement space of the whole vehicle is remarkably reduced, the use cost of a motor is reduced, the electronic pump is adopted for cooling, and the range extender is simple and reliable in overall structure and convenient to use. And mass production is easy to realize.

Description

Technical Field

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

[0002] At present, the charging infrastructure for new energy vehicles is not yet perfect, and pure electric vehicles generally have the problem of insufficient endurance. Therefore, range-extended electric vehicles have good development prospects. As the core component of a range-extended electric vehicle, a range extender generally consists of a high-efficiency engine, a generator, etc. To meet the needs of the overall vehicle space layout, the miniaturization, lightweight, and integration design of the range extender have become a new trend.

[0003] At present, the integration level of the range extender is very low, with the disadvantages of large occupied space and high cost, and it is not easy to mass-produce. Summary of the Utility Model

[0004] The utility model aims at the above problems and provides a range extender, which can solve one or more of the above technical problems.

[0005] According to one aspect of the utility model, a range extender is provided, including: an input shaft, a speed-increasing planetary gear set, a generator, and a cooling mechanism. The input shaft is connected to the engine, the input shaft is connected to the planet carrier of the speed-increasing planetary gear set, and the sun gear of the speed-increasing planetary gear set is connected to the motor shaft of the generator. The cooling mechanism includes a heat exchanger, an electronic pump, a suction filter, and an oil passage. The electronic pump is used to suck the oil from the suction filter and send it into the heat exchanger. The coolant in the heat exchanger cools the oil, and the cooled oil enters the oil passage.

[0006] In some embodiments, one end of the oil passage is connected to the liquid outlet of the heat exchanger, and the other end of the oil passage is respectively connected to the motor shaft, the spray pipe, and the speed-increasing planetary gear set.

[0007] In some embodiments, a planetary gear set support partition is provided between the input shaft and the speed-increasing planetary gear set. The planetary gear set support partition is used to support the bearing on the side of the input shaft close to the speed-increasing planetary gear set.

[0008] In some embodiments, a housing is further included. The housing includes a main housing, a front housing, and a rear housing. The main housing, the front housing, and the rear housing are connected by bolts. The main housing, the front housing, and the rear housing form a closed accommodation cavity. The input shaft, the speed-increasing planetary gear set, and the generator are arranged in the accommodation cavity.

[0009] In some embodiments, the motor controller of the generator is connected with a high-voltage connector. The high-voltage connector is fixed on the housing, and the high-voltage connector is connected with the motor three-phase line.

[0010] In some embodiments, the motor three-phase line is a rigid conductive copper bar, and the threaded fixed terminal of the motor three-phase line is fixedly connected with the high-voltage connector by bolts.

[0011] In some embodiments, after the high-voltage connector passes through the three-phase wire sealing cover plate, it is fixedly connected to the housing by bolts.

[0012] In some embodiments, the connection between the three-phase wire sealing cover plate and the high-voltage connector is sealed with sealant.

[0013] In some embodiments, a breather plug is provided on the housing.

[0014] In some embodiments, the motor controller of the generator is connected with a low-voltage connector.

[0015] The beneficial effects of the present utility model are as follows: By optimizing the overall structure of the range extender, the overall space and weight of the range extender are reduced. There is a speed increasing planetary gear set arranged coaxially, which significantly reduces the occupation of the vehicle layout space and reduces the use cost of the motor. The cooling is carried out by an electronic pump. The overall structure of the range extender is simple and reliable, and it is easy to realize mass production.

[0016] In addition, in the technical solution of the present utility model, unless otherwise specifically stated, the present technical solution can be realized by adopting conventional means in the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the specific embodiments of the present utility model, the following will briefly introduce the drawings required for use in the description of the specific embodiments. Obviously, the following drawings are some embodiments of the present utility model. For those of ordinary skill in the art, other drawings can be obtained according to these drawings without creative efforts.

[0018] Figure 1 It is a schematic structural diagram of the range extender provided by an embodiment of the present utility model.

[0019] Figure 2 It is a cross-sectional view of the range extender provided by an embodiment of the present utility model.

[0020] Figure 3 It is a side view of the range extender provided by an embodiment of the present utility model. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] In order to make the purpose, technical solutions and advantages of the present utility model clearer, the following further details the present utility model in conjunction with the drawings and embodiments. It should be understood that the specific embodiments described herein are some but not all embodiments of the present utility model, and are only used to explain the present utility model, not to limit the present utility model. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present utility model without creative efforts fall within the protection scope of the present utility model.

[0022] It should be noted that the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products, or devices.

[0023] Embodiment:

[0024] Refer to the attached Figures 1-3 to the specification, which shows a range extender provided by an embodiment of the present invention, including: an input shaft 9, a speed increasing planetary gear set 11, a generator 13, a cooling mechanism, and a housing.

[0025] Among them, the input shaft 9 is connected to the engine, the input shaft 9 is connected to the planet carrier of the speed increasing planetary gear set 11, the sun gear of the speed increasing planetary gear set 11 is connected to the motor shaft 12 of the generator 13, and the ring gear of the speed increasing planetary gear set 11 is fixed on the housing. Thus, after the engine transmits power to the input shaft 9, the rotor of the generator 13 is driven to generate electricity through the speed increasing planetary gear set 11 and the motor shaft 12.

[0026] The cooling mechanism may include a heat exchanger 3, an electronic pump 4, a suction filter 14, and an oil passage. The electronic pump 4 is used to suck the oil from the suction filter 14 and send it into the heat exchanger 3. The coolant in the heat exchanger 3 cools the oil, and the cooled oil enters the oil passage.

[0027] The housing includes a main housing 2, a front housing 1, and a rear housing 7. The main housing 2, the front housing 1, and the rear housing 7 are bolted together, and the main housing 2, the front housing 1, and the rear housing 7 form a sealed accommodation cavity. The input shaft 9, the speed increasing planetary gear set 11, and the generator 13 are arranged in the accommodation cavity.

[0028] In an alternative embodiment, the front housing 1 may be arranged on one side close to the input shaft 9, the rear housing 7 is arranged on one side of the generator 13 far from the speed increasing planetary gear set 11, and the main housing 2 is located between the front housing 1 and the rear housing 7.

[0029] In an alternative embodiment, the sun gear of the speed increasing planetary gear set 11 is splined to the motor shaft 12. Thus, the speed increasing planetary gear set 11 transmits torque to the motor shaft 12 through the sun gear. Compared with the traditional parallel shaft gear speed increasing mechanism, it can effectively save the layout space. Compared with the structure of directly connecting the input shaft to the motor, it can reduce the structural size of the selected motor and reduce the motor usage cost.

[0030] In an alternative embodiment, the generator 13 is an oil-cooled generator. Specifically, the electronic pump 4 can suck oil from the suction filter 14 and send it into the heat exchanger 3. The coolant in the heat exchanger 3 cools the oil, and the cooled oil enters the vehicle thermal management cycle from the liquid outlet of the heat exchanger.

[0031] After the cooled oil enters the oil passage from the liquid outlet of the heat exchanger, it can be divided into three paths. One path enters the motor shaft 12, which can cool the stator of the generator 13 and lubricate the bearings; one path enters the spray pipe to dissipate heat from the outgoing line end of the generator 13; and one path enters the planetary gear train 11 for cooling and lubrication.

[0032] In an alternative embodiment, the oil passage can be three oil passages. Each oil passage has one end connected to the liquid outlet of the heat exchanger 3, and the other ends of the three oil passages are respectively connected to the motor shaft 12, the spray pipe, and the planetary gear train 11. The oil passage can also be one oil passage. One end of the oil passage is connected to the liquid outlet of the heat exchanger 3, and the other end of the oil passage is provided with three branches respectively connected to the motor shaft 12, the spray pipe, and the planetary gear train 11.

[0033] In an alternative embodiment, a planetary gear train support partition 10 is provided between the input shaft 9 and the planetary gear train 11. The planetary gear train support partition 10 is used to support the bearing on the side of the input shaft 9 close to the planetary gear train 11.

[0034] The planetary gear train support partition 10 can be fixed to the main housing 2 by bolts. At this time, the planetary gear train support partition 10 can form an oil storage cavity around the planetary gear train 11. The oil storage cavity can accommodate the cooled oil, enabling the oil to play a role in cooling and lubricating the bearings and gears inside the planetary gear train 11.

[0035] In an alternative embodiment, the motor controller of the generator 13 is connected to a high-voltage connector 6. The high-voltage connector 6 is fixed to the rear housing 7, and the high-voltage connector 6 is connected to the motor three-phase line 16. The high-voltage connector 6 can be connected to the motor controller of the generator 13 through a wire harness.

[0036] The motor three-phase line 16 is a rigid conductive copper bar, and the threaded fixed terminal of the motor three-phase line 16 is fixedly connected to the high-voltage connector 6 by bolts. Thus, the connection structure between the high-voltage connector 6 and the motor three-phase line 16 is simple, reliable, economical, and practical.

[0037] After passing through the three-phase line sealing cover 15, the high-voltage connector 6 is fixedly connected to the housing by bolts. The connection between the three-phase line sealing cover 15 and the high-voltage connector 6 can be sealed with a sealant.

[0038] In an alternative embodiment, a breather plug 8 can be provided on the housing. Thus, the breather plug 8 is used to balance the air pressure inside and outside the range extender, so that the air pressure inside and outside the range extender is kept consistent.

[0039] In an alternative embodiment, the motor controller of the generator 13 is further connected to a low-voltage connector 5, and the low-voltage connector 5 may integrate an oil temperature sensor, a motor temperature sensor, and a motor resolver signal line.

[0040] The beneficial effects of the present utility model are as follows: By optimizing the overall structure of the range extender, the overall space and weight of the range extender are reduced. A speed-increasing planetary gear set arranged coaxially is provided, significantly reducing the occupation of the overall vehicle layout space and reducing the usage cost of the motor. An electronic pump is used for cooling, and the overall structure of the range extender is simple and reliable, and it is easy to achieve mass production.

[0041] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A range extender, characterized in that: include: An input shaft (9), a speed increasing planetary gear (11), a generator (13) and a cooling mechanism, The input shaft (9) is connected to the engine, the input shaft (9) is connected to the planet carrier of the speed-increasing planetary gear (11), and the sun gear of the speed-increasing planetary gear (11) is connected to the motor shaft (12) of the generator (13); The cooling mechanism comprises a heat exchanger (3), an electronic pump (4), a suction filter (14) and an oil channel. The electronic pump (4) is used to suck oil from the suction filter (14) and send it into the heat exchanger (3). The coolant in the heat exchanger (3) cools the oil, and the cooled oil enters the oil channel.

2. The range extender according to claim 1, characterized in that: One end of the oil channel is connected to the liquid outlet of the heat exchanger (3), and the other end of the oil channel is respectively connected to the motor shaft (12), the spray pipe and the speed increasing planetary gear (11).

3. The range extender according to claim 1, characterized in that: A planetary gear support partition (10) is provided between the input shaft (9) and the speed-increasing planetary gear (11), and the planetary gear support partition (10) is used to support the bearing of the input shaft (9) on one side close to the speed-increasing planetary gear (11).

4. The range extender according to claim 1, characterized in that: The invention also comprises a housing, wherein the housing comprises a main housing (2), a front housing (1) and a rear housing (7); the main housing (2), the front housing (1) and the rear housing (7) are connected by bolts; the main housing (2), the front housing (1) and the rear housing (7) form a sealed accommodating chamber; the input shaft (9), the speed increasing planetary gear (11) and the generator (13) are arranged in the accommodating chamber.

5. The range extender according to claim 4, characterized in that: The motor controller of the generator (13) is connected to a high-voltage connector (6), the high-voltage connector (6) is fixed on the housing, and the high-voltage connector (6) is connected to the motor three-phase line (16).

6. The range extender according to claim 5, characterized in that: The motor three-phase wire (16) is a hard conductive copper bar, and the threaded fixed terminal of the motor three-phase wire (16) is fixedly connected to the high-voltage connector (6) by means of bolts.

7. The range extender according to claim 5, characterized in that: The high-voltage connector (6) is fixedly connected to the housing by means of bolts after passing through the three-phase line sealing cover plate (15).

8. The range extender according to claim 7, characterized in that: The connection between the three-phase line sealing cover plate (15) and the high-voltage connector (6) is sealed with a sealant.

9. The range extender according to claim 1, characterized in that: A vent plug (8) is provided on the shell.

10. The range extender according to claim 1, characterized in that: The motor controller of the generator (13) is connected to a low-voltage connector (5).

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