Range extender assembly

Abstract

The utility model provides a range extender assembly 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 water inlet, a cooling loop and a water outlet, the cooling loop is arranged on the shell, and cooling liquid sequentially passes through the water inlet, the cooling loop and the water outlet and then enters the whole vehicle thermal management cycle. According to the range extender assembly provided by the utility model, the overall structure of the range extender assembly is optimized, the overall space and weight of the range extender assembly 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, a mechanical pump is adopted for cooling, the cost is saved, and the service life of the motor is prolonged. The three-phase line connection of the motor is reliable, arrangement and assembly with a whole vehicle are facilitated, arrangement space and cost are saved, 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 assembly. Background Art

[0002] With the continuous development of new energy vehicles, electric vehicles with obvious energy-saving and environmental protection advantages have become a hot spot. In the current situation where the charging infrastructure is not yet perfect and the driving range of pure electric vehicles still has significant shortcomings, the investment and use of range extenders have become one of the ways to solve the above problems at the current stage.

[0003] 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 and lightweight design of the range extender have become a new trend. Currently, the range extender assembly has the disadvantages of large occupied space and high cost, and 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 assembly, which can solve one or more of the above technical problems.

[0005] According to one aspect of the utility model, there is provided a range extender assembly, 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 water inlet, a cooling circuit, and a water outlet. The cooling circuit is arranged on the housing. After the coolant passes through the water inlet, the cooling circuit, and the water outlet in sequence, it enters the vehicle thermal management cycle.

[0006] In some embodiments, the cooling mechanism further includes a mechanical pump, which is driven by the motor shaft and is used to suck the oil from the suction filter into the oil passage. 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 front cover plate is arranged on one side of the speed increasing planetary gear set close to the input shaft.

[0008] In some embodiments, the housing includes a main housing and a rear housing. The rear housing is arranged on the side of the generator away from the speed increasing planetary gear set. The main housing and the rear housing are connected by bolts. The main housing and the rear housing form a sealed accommodation cavity, and the speed increasing planetary gear set and the generator are arranged in the accommodation cavity.

[0009] In some embodiments, the mechanical pump is arranged on the rear housing.

[0010] In some embodiments, the mechanical pump includes a mechanical pump cover plate, on which a pressure limiting valve is integrated. The mechanical pump cover plate is fixed to the rear housing by bolts.

[0011] In some embodiments, the cooling circuit adopts a vortex design.

[0012] In some embodiments, a cooling circuit cover plate is provided on the side of the cooling circuit away from the housing.

[0013] In some embodiments, a three-phase terminal block is provided on the housing. The three-phase motor wires pass through the three-phase terminal block and are connected to a three-phase adapter terminal block. Conductive copper posts are provided in the three-phase adapter terminal block. One end of the conductive copper post is connected to the three-phase motor wires, and the other end of the conductive copper post is connected to a high-voltage wire harness.

[0014] In some embodiments, the end of the conductive copper post connected to the high-voltage wire harness is led out through a sealed joint.

[0015] The beneficial effects of the present utility model are as follows: By optimizing the overall structure of the range extender assembly, the overall space and weight of the range extender assembly 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 use cost of the motor. Mechanical pumps are used for cooling, saving costs. The connection of the three-phase motor wires is reliable, which is beneficial for the vehicle layout and assembly to save layout space and costs, and is easy to achieve mass production.

[0016] In addition, in the technical solution of the present utility model, unless otherwise specifically stated, the 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 based on these drawings without creative efforts.

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

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

[0020] Figure 3 It is a side view of the range extender assembly provided by an embodiment of the present utility model.

[0021] Figure 4 It is a schematic structural diagram of the three-phase terminal block of the range extender assembly provided by an embodiment of the present utility model.

[0022] Figure 5 It is a schematic structural diagram of the three-phase motor wires of the range extender assembly provided by an embodiment of the present utility model. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0023] In order to make the objectives, technical solutions and advantages of the present utility model clearer and more understandable, the present utility model will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are part of the embodiments of the present utility model, rather than all of the embodiments, 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 shall fall within the protection scope of the present utility model.

[0024] It should be noted that the terms "include" and "have" 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 does not necessarily have to be 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.

[0025] Embodiment:

[0026] Refer to the attached Figures 1-5 drawings, which show a range extender assembly provided by an embodiment of the present utility model, including: an input shaft, a speed increasing planetary gear set 11, a generator 17, a cooling mechanism and a housing.

[0027] Among them, the input shaft is connected to the engine, the input shaft 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 13 of the generator 17, 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, the generator 17's rotor is driven to generate electricity through the speed increasing planetary gear set 11 and the motor shaft 13.

[0028] The cooling mechanism may include a water inlet 4, a cooling circuit 18, a water outlet 3 and a mechanical pump 14. In an alternative embodiment, the generator 17 may be an oil-cooled generator. The cooling circuit 18 is arranged on the housing, and the coolant enters the cooling circuit 18 through the water inlet 4. The cooling circuit 18 may adopt a vortex design to reduce the outflow speed of the coolant and increase the contact area with the housing, which can effectively take away the heat of the hot oil in the housing. After flowing through the cooling circuit 18, the coolant flows out from the water outlet 3 and enters the vehicle's thermal management cycle.

[0029] The mechanical pump 14 can be driven by the motor shaft 13. The mechanical pump 14 can suck the oil from the suction filter 16 into the oil passage. The oil passage is located inside. After the oil is sucked into the oil passage, it can be divided into three paths. One path enters the motor shaft 13 to cool the stator of the generator 17 and lubricate the bearing; one path enters the spray pipe 12 to dissipate heat from the outgoing line end of the generator 17; one path enters the speed increasing planetary gear set 11 for cooling and lubrication.

[0030] Thus, the mechanical pump 14 circulates the oil in the housing, and at the same time, the cooling circuit 18 cools the oil in the housing. The mechanical pump 14 is more economical and reliable, and the cost of the cooling circuit 18 is lower, effectively reducing the cost while reducing the space occupied by the vehicle layout.

[0031] In an alternative embodiment, after the power of the engine passes through the input shaft, it is connected to the motor shaft 13 through the spline of the sun gear of the speed increasing planetary gear set 11, thereby realizing the torque transmission. Compared with the speed increasing mechanism of parallel shaft gears, the layout space is effectively saved. Compared with the direct connection motor scheme, the structural size of the selected motor is reduced, and the motor usage cost is reduced.

[0032] In an alternative embodiment, a front cover plate 10 is provided on one side of the speed increasing planetary gear set 11 close to the input shaft. Thus, a semi-sealed oil storage cavity is formed between the front cover plate 10 and the speed increasing planetary gear set 11. The oil storage cavity can accommodate oil, and the oil plays a role in cooling and lubricating the bearings and gears inside the speed increasing planetary gear set 11.

[0033] The front cover plate 10 can be connected to the housing by bolts.

[0034] In an alternative embodiment, the housing may include a main housing 1 and a rear housing 7. The rear housing 7 is arranged on the side of the generator 17 away from the speed increasing planetary gear set 11. The main housing 1 and the rear housing 7 are connected by bolts. The main housing 1, the rear housing 7 and the front cover plate 10 jointly form a closed accommodation cavity, and the speed increasing planetary gear set 11 and the generator 17 are arranged in the accommodation cavity.

[0035] In an alternative embodiment, the mechanical pump 14 is arranged on the rear housing 7. The mechanical pump 14 includes a mechanical pump cover plate 6. A pressure limiting valve can be integrated on the mechanical pump cover plate 6, and the mechanical pump cover plate 6 can be fixed on the rear housing 7 by bolts.

[0036] In an alternative embodiment, a cooling circuit cover plate 15 can be arranged on the side of the cooling circuit 18 away from the housing. Thus, excessive heat exchange between the cooling circuit 18 and the external environment is avoided, which affects the cooling effect, and the cooling efficiency is effectively improved.

[0037] In an alternative embodiment, a three-phase terminal block 20 is arranged on the housing. Specifically, the three-phase terminal block 20 can be fixedly connected to the rear housing 7 by bolts.

[0038] The three-phase wires 25 of the motor pass through the three-phase wiring base 20 and are then connected to the three-phase adapter base 19. Conductive copper posts 24 can be arranged in the three-phase adapter base 19, and a radial sealing ring 23 is used for sealing between the three-phase adapter base 19 and the conductive copper posts 24. One end of the conductive copper post 24 is connected to the terminal of the three-phase wires 25 of the motor, the other end of the conductive copper post 24 is connected to the terminal of the high-voltage wire harness 22, and the end of the conductive copper post 24 connected to the high-voltage wire harness 22 is led out through a sealing joint 21.

[0039] A three-phase wire cover plate 8 is further arranged on the rear housing 7. The three-phase wire cover plate 8 is used to cover the three-phase wiring base 20 and the three-phase adapter base 19. The three-phase wire cover plate 8 is fixed to the rear housing 7 by bolts, and the end face of the three-phase wire cover plate 8 is sealed with sealant.

[0040] In an alternative embodiment, a vent plug 9 is arranged on the housing for balancing the air pressure inside and outside the housing so that the air pressure inside and outside the housing remains the same.

[0041] In an alternative embodiment, a first low-voltage connector 2 is arranged on the housing for integrating the oil temperature sensor and the motor temperature sensor; a second low-voltage connector 5 can also be arranged on the housing, and the second low-voltage connector 5 is used for connecting the signal wires of the motor resolver.

[0042] The beneficial effects of the present utility model are as follows: By optimizing the overall structure of the range extender assembly, the overall space and weight of the range extender assembly are reduced. A speed-increasing planetary gear set arranged coaxially is provided, significantly reducing the occupation of the vehicle layout space, reducing the use cost of the motor, using a mechanical pump for cooling to save costs, the connection of the three-phase wires of the motor is reliable, which is beneficial to saving the layout space and cost for vehicle layout and assembly, and is easy to achieve mass production.

[0043] 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. The range extender assembly is characterized by: include: An input shaft, a speed increasing planetary gear (11), a generator (17) 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 (11), and the sun gear of the speed-increasing planetary gear (11) is connected to the motor shaft (13) of the generator (17); The cooling mechanism comprises a water inlet (4), a cooling circuit (18) and a water outlet (3); the cooling circuit (18) is arranged on the housing; the coolant passes through the water inlet (4), the cooling circuit (18) and the water outlet (3) in sequence and then enters the thermal management cycle of the whole vehicle.

2. The range extender assembly according to claim 1, characterized in that: The cooling mechanism also includes a mechanical pump (14), which is driven by the motor shaft (13) and is used to suck oil from the suction filter (16) into an oil channel, wherein the oil channel is respectively connected to the motor shaft (13), the spray pipe (12) and the speed increasing planetary gear (11).

3. The range extender assembly according to claim 1, characterized in that: A front cover plate (10) is provided on a side of the speed increasing planetary gear (11) close to the input shaft.

4. The range extender assembly according to claim 2, characterized in that: The housing comprises a main housing (1) and a rear housing (7); the rear housing (7) is arranged on a side of the generator (17) away from the speed-increasing planetary gearbox (11); the main housing (1) and the rear housing (7) are connected by bolts; the main housing (1) and the rear housing (7) form a sealed accommodating cavity; the speed-increasing planetary gearbox (11) and the generator (17) are arranged in the accommodating cavity.

5. The range extender assembly according to claim 4, characterized in that: The mechanical pump (14) is arranged on the rear housing (7).

6. The range extender assembly according to claim 4, characterized in that: The mechanical pump (14) comprises a mechanical pump cover plate (6), a pressure limiting valve is integrated on the mechanical pump cover plate (6), and the mechanical pump cover plate (6) is fixed to the rear housing (7) by means of bolts.

7. The range extender assembly according to claim 1, characterized in that: The cooling circuit (18) adopts a vortex design.

8. The range extender assembly according to claim 1, characterized in that: A cooling circuit cover plate (15) is provided on a side of the cooling circuit (18) away from the housing.

9. The range extender assembly according to claim 1, characterized in that: A three-phase terminal block (20) is arranged on the shell, and a three-phase line (25) of the motor passes through the three-phase terminal block (20) and is connected to a three-phase switching terminal block (19). A conductive copper column (24) is arranged in the three-phase switching terminal block (19), one end of the conductive copper column (24) is connected to the three-phase line (25) of the motor, and the other end of the conductive copper column (24) is connected to a high-voltage wire harness (22).

10. The range extender assembly according to claim 9, characterized in that: One end of the conductive copper column (24) connected to the high-voltage wire harness (22) is connected through a sealed joint (21).

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