Automobile range extender and automobile
By installing the GCU controller on the top of the generator and redesigning the installation location of the exhaust gas recirculation system, the problems of low space utilization and difficult routing of generators and GCU controllers in extended-range cars are solved, and cost savings and production efficiency improvements are achieved.
Patent Information
- Application Number
- CN202422477359.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-14
- Publication Date
- 2025-08-01
- Estimated Expiration
- 2034-10-14
AI Technical Summary
In the prior art, the generator and GCU controller of extended-range vehicles adopt a split layout structure, resulting in low space utilization in the cabin, and high-voltage three-phase wiring is difficult and costly.
The controller housing of the GCU controller is fixedly installed on the top of the generator and electrically connected by a copper drain. The exhaust gas recirculation system body is fixed to the exhaust side side wall of the engine cylinder block through a transition bracket. The installation position of the exhaust gas recirculation system is redesigned to avoid interference, and a copper drain is used instead of the high-pressure three-phase wire.
It improves the utilization rate of automobile space, reduces costs, simplifies the difficulty of routing, solves the interference problem between generators and GCU controllers, and improves production efficiency.
Smart Images
Figure CN223177645U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of automobiles, and more particularly, to an automotive range extender and an automobile. Background Art
[0002] At present, the generator 3 and the GCU controller 1 on the range-extended electric vehicle are of a split structure. The GCU controller 1 is the range extender generator controller. The generator 3 on the range extender can be fixedly connected to the engine 2 by bolts, and the GCU controller 1 is arranged at a suitable position in the engine compartment or on the vehicle body. As Figure 6 shown, in the prior art, the range extender generator 3 and the GCU controller 1 need to be connected by a high-voltage three-phase line 16; in the prior art, an exhaust gas recirculation system is installed on the range extender engine 2, and the exhaust gas recirculation system includes an exhaust gas recirculation system body 5. As Figures 6-7 shown, in the prior art, the exhaust gas recirculation system body 5 on the range extender engine 2 is generally fixedly installed on the cylinder head on the side of the engine 2 close to the generator 3, that is, above the generator 3, and is integrally and rigidly connected to the cylinder head.
[0003] At present, the generator 3 and the GCU controller 1 on the range-extended electric vehicle adopt a split layout structure, which results in low utilization rate of the space in the vehicle engine compartment. Moreover, the generator and the controller are connected by a high-voltage three-phase line 16, which makes the wiring difficult and costly. Summary of the Invention
[0004] The purpose of the utility model is to provide an automotive range extender and an automobile, so as to overcome the problems of low utilization rate of the space in the vehicle engine compartment and difficult and costly wiring of the high-voltage three-phase line existing in the split layout structure of the generator and the GCU controller on the automotive range extender in the prior art.
[0005] The utility model is realized by the following technical solutions. An automotive range extender includes a GCU controller, an engine and a generator which are connected to each other. An exhaust gas recirculation system is installed on the engine. The GCU controller includes a controller housing which is fixedly installed on the top of the generator. The exhaust gas recirculation system includes an exhaust gas recirculation system body. The air inlet and the exhaust outlet of the exhaust gas recirculation system body are respectively connected to an exhaust pipe and an intake pipe. The exhaust gas recirculation system body is fixedly installed on the side wall of the engine block.
[0006] Further, the controller housing is fixedly connected to the top of the generator by bolts.
[0007] Further, the GCU controller is electrically connected to the generator by a copper busbar.
[0008] [[ID=
[0009] Furthermore, the main body of the exhaust gas recirculation system is fixedly connected to a transition bracket and fixedly installed on the side wall of the engine block through the transition bracket. The transition bracket and the main body of the exhaust gas recirculation system are fixedly connected by welding.
[0010] Furthermore, the main body of the exhaust gas recirculation system is installed on the side wall of the exhaust side of the engine block.
[0011] Furthermore, a fixed boss is installed on the side wall of the engine block on the exhaust side. The fixed boss is located below the exhaust manifold of the engine. The transition bracket is connected to the fixed boss by bolts.
[0012] Furthermore, one end of the exhaust pipe is fixedly connected to the catalytic converter housing by welding, and the other end of the exhaust pipe is connected to the air inlet of the main body of the exhaust gas recirculation system by bolts.
[0013] Furthermore, a corrugated pipe section is provided on the exhaust pipe.
[0014] A vehicle includes the above-mentioned vehicle range extender.
[0015] Compared with the prior art, the beneficial effects of the present utility model are as follows:
[0016] 1. By fixedly installing the controller housing of the GCU controller on the top of the generator and electrically connecting the GCU controller and the generator through a copper busbar, the generator and the GCU controller are integrated into one part, which improves the space utilization rate of the vehicle, saves costs by avoiding the use of high-voltage three-phase wires, and solves the problem of difficult routing of high-voltage three-phase wires.
[0017] 2. In the prior art, the exhaust gas recirculation system body in the exhaust gas recirculation system is generally arranged on the cylinder head of the engine near the generator side. The part of the exhaust gas recirculation system body protruding from the engine will occupy part of the top space of the generator. After the GCU controller is arranged above the generator in the present utility model, if the layout structure of the exhaust gas recirculation system body on the engine in the prior art is adopted, the exhaust gas recirculation system body will interfere with the GCU controller to a certain extent. The clearance between the fastening screws of the top cover plate of the GCU controller and the exhaust gas recirculation system body is small, which affects the disassembly and assembly of the top cover plate of the GCU controller, resulting in a slow rhythm and low production efficiency during the production and assembly process of the high-voltage DC bus; for this reason, in the present utility model, the exhaust gas recirculation system body in the exhaust gas recirculation system is fixedly installed on the side wall of the exhaust side of the engine cylinder block through a transition bracket, and the height of the exhaust port of the exhaust gas recirculation system body is greater than the height of the intake port, that is, the exhaust gas recirculation system body is arranged to incline downward along the direction from the exhaust port to the intake port. By redesigning the installation position of the exhaust gas recirculation system body, the present utility model well solves the problem that the exhaust gas recirculation system body in the exhaust gas recirculation system is prone to interference with the GCU controller. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 is the front view of the range extender of the present utility model;
[0019] Figure 2 is Figure 1 the partial enlarged view of part Ⅰ in
[0020] Figure 3 is the left view of the range extender of the present utility model;
[0021] Figure 4 is the partial structure schematic diagram of the range extender of the present utility model in the right view direction;
[0022] Figure 5 is the connection schematic diagram of the intake pipe 7 and the exhaust pipe 12 of the exhaust gas recirculation system of the present utility model;
[0023] Figure 6 is the layout structure schematic diagram of the GCU controller 1 and the exhaust gas recirculation system on the range extender engine 2 in the prior art;
[0024] Figure 7 is Figure 6 the partial enlarged view of part Ⅱ in
[0025] In the figure: 1. GCU controller; 2. Engine; 3. Generator; 4. Controller housing; 5. Exhaust gas recirculation system body; 6. Exhaust pipe; 7. Intake pipe; 8. Transition bracket; 9. Catalytic converter housing; 10. Bellows section; 11. Fixed boss; 12. Exhaust pipe line; 13. Exhaust port; 14. Intake port; 15. Exhaust manifold; 16. High-voltage three-phase line. Detailed implementation manners
[0026] In order to enable those skilled in the art of this technology to better understand the technical solutions in the present utility model, the following will clearly and completely describe the technical solutions in the embodiments of the present utility model with reference to the accompanying drawings in the embodiments of the present utility model. Based on the embodiments in the present utility model, all other embodiments obtained by those of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present utility model.
[0027] An automotive range extender includes a GCU controller 1, an engine 2 and a generator 3 which are connected to each other, and an exhaust gas recirculation system is installed on the engine 2.
[0028] The GCU controller 1 includes a controller housing 4, the controller housing 4 is fixedly installed on the top of the generator 3, the controller housing 4 and the top of the generator 3 are fixedly connected by bolts, and bolt mounting holes are provided on both the controller housing 4 and the top of the generator 3. The GCU controller 1 is electrically connected to the generator 3 through a copper busbar. In the present utility model, by fixedly installing the controller housing 4 of the GCU controller 1 on the top of the generator 3 and electrically connecting the GCU controller 1 to the generator 3 through a copper busbar, the generator 3 and the GCU controller 1 are integrated into one part, improving the space utilization rate of the vehicle, while also avoiding the use of the high-voltage three-phase line 16, saving costs, and avoiding the problem of difficult routing of the high-voltage three-phase line 16.
[0029] The exhaust gas recirculation system includes an exhaust gas recirculation system body 5, the intake port 14 and the exhaust port 13 of the exhaust gas recirculation system body 5 are respectively connected to an exhaust pipe 6 and an intake pipe 7, and the height of the exhaust port 13 of the exhaust gas recirculation system body 5 is greater than the height of the intake port 14 of the exhaust gas recirculation system body 5, that is, the exhaust gas recirculation system body 5 is inclined downward in the direction from the exhaust port 13 to the intake port 14.
[0030] In the prior art, the exhaust gas recirculation system body 5 in the exhaust gas recirculation system is generally arranged on the cylinder head of the engine 2 close to the generator 3. The part of the exhaust gas recirculation system body 5 protruding from the engine 2 will occupy part of the top space of the generator 3. After the GCU controller 1 is arranged above the generator 3 in the present utility model, if the exhaust gas recirculation system body 5 on the engine 2 is arranged according to the structure in the prior art, there will be a certain interference between the exhaust gas recirculation system body 5 and the GCU controller 1. The clearance between the fastening screws of the top cover plate of the GCU controller 1 and the exhaust gas recirculation system body 5 is small, which affects the disassembly and assembly of the top cover plate of the GCU controller 1, resulting in a slow assembly rhythm and low production efficiency when assembling the high-voltage DC bus during the production process. Therefore, in the present utility model, the exhaust gas recirculation system body 5 in the exhaust gas recirculation system is fixedly installed on the side wall of the exhaust side of the engine 2 cylinder block through a transition bracket 8. The exhaust gas recirculation system body 5 is fixedly connected to the transition bracket 8 and fixedly installed on the side wall of the engine 2 cylinder block through the transition bracket 8. The transition bracket 8 is fixedly connected to the exhaust gas recirculation system body 5 by welding. The exhaust gas recirculation system body 5 is installed on the side wall of the exhaust side of the engine 2 cylinder block, and the exhaust gas recirculation system body 5 is below the exhaust manifold 15 of the engine 2. A fixed boss 11 is installed on the side wall of the engine 2 cylinder block at the exhaust side. The fixed boss 11 is below the exhaust manifold 15 of the engine 2. The transition bracket 8 is connected to the fixed boss 11 by bolts. <{
[0031] By redesigning the installation position of the exhaust gas recirculation system body 5 in the exhaust gas recirculation system, the present utility model effectively solves the problem of interference between the exhaust gas recirculation system body 5 and the GCU controller 1.
[0032] One end of the exhaust pipe 6 is fixedly connected to the catalytic converter housing 9 by welding, and the other end of the exhaust pipe 6 is connected to the air inlet 14 of the exhaust gas recirculation system body 5 by bolts. In the present utility model, the catalytic converter housing 9 is installed on the exhaust pipe line 12 of the engine.
[0033] A corrugated pipe section 10 is provided on the exhaust pipe 6. By providing the corrugated pipe section 10 on the exhaust pipe 6, while improving the assembly error tolerance rate of the exhaust gas recirculation system body 5, the stress concentration of the bracket and the pipeline can be reduced, and the cracking risk of the bracket and the pipeline caused by engine vibration can be lowered.
[0034] An automobile includes the above-mentioned automobile range extender.
Claims
1. An automotive range extender, comprising a GCU controller (1), an engine (2) and a generator (3) which are interconnected, wherein an exhaust gas recirculation system is installed on the engine (2), and is characterized in that, The GCU controller (1) includes a controller housing (4), the controller housing (4) is fixedly installed on the top of the generator (3), the exhaust gas recirculation system includes an exhaust gas recirculation system body (5), the intake port (14) and the exhaust port (13) of the exhaust gas recirculation system body (5) are respectively connected to the exhaust pipe (6) and the intake pipe (7), and the exhaust gas recirculation system body (5) is fixedly installed on the side wall of the engine (2) cylinder block.
2. The range extender for a vehicle according to claim 1, wherein, The controller housing (4) is fixedly connected to the top of the generator (3) by bolts.
3. An automotive range extender according to claim 1, wherein The GCU controller (1) is electrically connected to the generator (3) through a copper busbar.
4. An automotive range extender according to claim 1, characterized in that, The height of the exhaust port (13) of the exhaust gas recirculation system body (5) is greater than the height of the intake port (14) of the exhaust gas recirculation system body (5).
5. An automotive range extender according to claim 1, characterized in that, The exhaust gas recirculation system body (5) is fixedly connected to a transition bracket (8) and is fixedly installed on the side wall of the engine (2) cylinder block through the transition bracket (8), and the transition bracket (8) is fixedly connected to the exhaust gas recirculation system body (5) by welding.
6. The range extender for a vehicle according to claim 5, wherein, The exhaust gas recirculation system body (5) is installed on the side wall of the exhaust side of the engine (2) cylinder block.
7. An automotive range extender according to claim 6, wherein, A fixed boss (11) is installed on the side wall of the engine (2) cylinder block on the exhaust side, the fixed boss (11) is on the lower side of the exhaust manifold (15) of the engine (2), and the transition bracket (8) is connected to the fixed boss (11) by bolts.
8. An automotive range extender according to claim 7, characterized in that, One end of the exhaust pipe (6) is fixedly connected to the catalytic converter housing (9) by welding, and the other end of the exhaust pipe (6) is connected to the intake port (14) of the exhaust gas recirculation system body (5) by bolts.
9. An automotive range extender according to claim 7, characterized in that, A corrugated pipe section (10) is provided on the exhaust pipe (6).
10. A vehicle, characterized in that, An automotive range extender according to any one of claims 1-9 is included.