Range extender system and range-extended automobile

Abstract

The range extender system comprises an electric generator, an engine and a sealing end plate, in the distribution direction of the engine and the electric generator, one end of an output crankshaft of the engine extends out of a cylinder body through a mounting hole, and the other end of the output crankshaft of the engine is connected with a rotor of the electric generator; the sealing end plate is provided with a hole channel for the output crankshaft to pass through, the sealing end plate is located between the engine and the generator and used for sealing a gap between the motor and the engine, and cooling oil in a cavity of the generator can be blocked by the sealing end plate when sputtering towards the direction of the engine. The sealing performance of the connecting position of the engine and the generator is improved, the risk that cooling oil leaks through a gap is reduced, the stability of the heat dissipation effect of the generator is improved, and the risk that the generator, the range extender system and the range-extended automobile are degraded in function and even fail due to the fact that the temperature of the generator is high is reduced.

Description

Technical Field

[0001] The present application relates to the field of new energy vehicle technology, and in particular to a range extender system and an extended-range vehicle. Background Art

[0002] With the rapid development of new energy technologies, new energy vehicles are being used more and more widely. New energy vehicles include batteries and electric motors. Batteries are used to supply power to electric motors, and electric motors are used to drive the vehicle. The vehicle's range is an important criterion for judging new energy vehicles. As the requirements for vehicle range continue to increase, extended-range vehicles are gradually emerging.

[0003] The range extender system is a key component of extended-range vehicles, including an engine and a generator. The generator can convert the mechanical energy of the engine's rotation into electrical energy and store the electrical energy in the battery to charge the battery, which gives the vehicle a longer range, solves the range anxiety problem of pure electric vehicles, and also gives the vehicle the driving experience of a pure electric vehicle, that is, there is no power setback or interruption during driving, making extended-range vehicles a technical route chosen by more and more car companies.

[0004] In the range extender system, the cooling methods of the generator include water cooling and oil cooling. In the oil-cooled motor, there is cooling oil inside the generator. The cooling oil will flow through the stator, winding, rotor and other heat-generating components and take away its heat to achieve the cooling of the generator. If the range extender system is a direct-connected range extender system, that is, the output crankshaft of the engine is directly connected to the rotor, it is necessary to remove the upper cover of the generator housing, so that the inner cavity of the generator is opened and the internal stator and rotor are exposed to facilitate the connection of the output crankshaft and the rotor. At this time, the generator housing cannot form a closed component, and there is a risk of cooling oil leakage. The leakage of cooling oil will cause the cooling effect of the generator to deteriorate, the temperature to rise, and even the risk of failure.

[0005] Therefore, how to improve the sealing performance of the direct-connected range extender system is a technical problem that needs to be urgently solved in the range extender system. Utility Model Content

[0006] The present application provides a range extender system and a range extender vehicle, which can improve the sealing performance of the range extender system.

[0007] A first aspect of the present application provides a range extender system, comprising a generator, an engine and a sealing end plate, the generator comprising at least a housing, a stator and a rotor, the stator and the rotor being mounted on the housing and located in a cavity surrounded by the housing, the engine comprising at least a cylinder block and an output crankshaft, the cylinder block being connected to the housing, one end of the output crankshaft extending out of the cylinder block through a mounting hole of the cylinder block along the distribution direction of the engine and the generator, and the other end being directly connected to the rotor, a hole for the output crankshaft to pass through being provided on the sealing end plate, the sealing end plate being located between the engine and the generator along the distribution direction of the engine and the generator, the sealing end plate being used to seal the gap between the generator and the engine.

[0008] In the present application, the sealing end plate is used to seal the gap between the generator and the engine. The cooling oil in the cavity of the generator can be blocked by the sealing end plate when it splashes toward the engine, thereby improving the sealing of the connection between the engine and the generator, thereby reducing the risk of cooling oil leakage through the gap, thereby improving the stability of the heat dissipation effect of the generator, and further reducing the risk of functional degradation or even failure of the generator, range extender system and extended-range vehicle due to high generator temperature.

[0009] In a possible design, the sealing end plate includes a main body portion and a connecting portion. Along the radial direction of the sealing end plate, the connecting portion is located outside the main body portion, and the connecting portion is clamped and fixed by the cylinder body and the shell.

[0010] In the present application, the connection part is clamped and fixed by the cylinder body and the shell, reducing the risk of the sealing end plate detaching from the engine and the generator, thereby improving the stability of the connection between the sealing end plate and the engine and the generator, and further helping to improve the sealing of the connection position between the engine and the generator, and reducing the risk of cooling oil in the generator cavity leaking through the connection position between the engine and the generator.

[0011] In a possible design, the cylinder body and the housing are fixedly connected by a first fastener, and a first through hole for the first fastener to pass through is provided at the connection portion.

[0012] In the present application, a portion of the first fastener is located in the first through hole, and the first fastener can limit the sealing end plate, thereby reducing the risk of displacement or even separation from the generator and engine during the installation, transportation, and use of the range extender system, thereby further improving the connection stability between the sealing end plate and the engine and generator, and thus helping to improve the sealing of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leakage.

[0013] In one possible design, the main body includes a first body and a second body, the second body is located between the first body and the connecting portion, one end of the second body is connected to the connecting portion, and the other end of the second body is connected to the first body, the second body is inclined along the distribution direction of the engine and the generator, and the channel is located on the first body; in the distribution direction of the engine and the generator, the first body abuts against the cylinder body, and the first body and the cylinder body are fixedly connected by a second fastener.

[0014] In this application, the connection portion of the sealing end plate is clamped by the engine cylinder block and the generator housing. Simultaneously, the first body abuts the engine cylinder block, reducing the risk of the engine and generator's forces acting on the sealing end plate being concentrated entirely at the connection portion. This reduces the risk of damage to the connection portion during operation of the range extender system and extends the service life of the sealing end plate. The first body is fixedly connected to the cylinder block, further enhancing the stability of the connection between the sealing end plate and the engine and generator, thereby improving the sealing performance of the connection between the engine and generator and reducing the risk of cooling oil leakage.

[0015] In a possible design, the range extender system further includes a first seal, which is located between the sealing end plate and the housing, and the first seal is located on the inner side of the cylinder.

[0016] In the present application, the first seal can reduce the risk of the cooling oil inside the generator entering the engine through the gap between the casing and the sealing end plate and the first fastener, and reduce the risk of the cooling oil inside the generator overflowing to the outside through the gap between the casing and the sealing end plate, thereby improving the sealing of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leakage.

[0017] In one possible design, the range extender system also includes a first oil seal, which is located in the channel. Along the radial direction of the sealing end plate, one side of the first oil seal abuts against the side wall of the channel, and the other side of the first oil seal abuts against the output crankshaft.

[0018] In the present application, the first oil seal can seal the gap between the output crankshaft and the sealing end plate, thereby reducing the risk of the cooling oil in the generator entering the outside world or the engine through the gap between the output crankshaft and the sealing end plate, thereby improving the sealing of the connection position between the engine and the generator.

[0019] In one possible design, the first body includes an oil seal mounting portion, which extends toward the housing along the distribution direction of the engine and the generator. The oil seal mounting portion forms a channel, and the first oil seal abuts against the oil seal mounting portion along the radial direction of the sealing end plate.

[0020] In the present application, when the thickness of the sealing end plate is small, an oil seal mounting portion extending along the distribution direction of the engine and the generator is provided, which can increase the length of the channel so that the length of the channel meets the installation dimension requirements of the first oil seal, reducing the risk of difficulty or even inability to install the first oil seal due to the small length of the channel. In addition, on the premise that the length of the channel meets the installation dimension requirements of the first oil seal, the thickness of the edge position of the sealing end plate can also be reduced, which is beneficial to reducing the overall weight of the sealing end plate and the range extender system.

[0021] In one possible design, the range extender system also includes a second oil seal, at least part of which is located in the mounting hole. Along the radial direction of the output crankshaft, one side of the second oil seal abuts the cylinder body, and the other side of the second oil seal abuts the output crankshaft; the cylinder body and the sealing end plate form a first cavity, and there is a second cavity between the first oil seal and the second oil seal; a first ventilation channel is provided on the sealing end plate, and the second cavity is connected to the first cavity through the first ventilation channel; a second ventilation channel is provided on the cylinder body, and the first cavity is connected to the outside world through the second ventilation channel.

[0022] In the present application, the first cavity is connected to the outside world through the second ventilation channel, and the first cavity is connected to the second cavity through the first ventilation channel to balance the pressure between the second cavity and the outside world, thereby reducing the risk of deformation of the first oil seal and the second oil seal under the action of the pressure difference, resulting in sealing failure.

[0023] In one possible design, the first exhaust channel is arranged on the side of the sealing end plate facing the cylinder body; the cylinder body includes a main body and a mounting portion, the mounting portion is located on the outer periphery of the main body, the mounting portion and the sealing end plate form a first cavity, the mounting portion is connected to the shell, and the second ventilation channel is arranged in the mounting portion and passes through the mounting portion along the radial direction of the cylinder body.

[0024] In the present application, the second ventilation channel is arranged on the mounting portion for connecting to the shell, and the shell can cover a portion of the second ventilation channel, thereby reducing the area of the second ventilation channel exposed to the outside world, and further reducing the risk of external liquid entering the range extender system through the second ventilation channel.

[0025] In a possible design, the second ventilation channel has a curved profile.

[0026] In the present application, when there is condensed water, rainwater or other liquids on the outside of the cylinder body, the side wall of the second ventilation channel can block at least part of the liquid, thereby reducing the risk of external liquid entering the engine through the second ventilation channel, and also reducing the risk of external liquid entering between the cylinder body and the sealing end plate through the second ventilation channel and the first ventilation channel, thereby reducing the risk of external liquid entering the interior of the generator through the gap between the sealing end plate and the shell, thereby improving the waterproof performance of the range extender system.

[0027] A second aspect of the present application provides an extended-range vehicle, comprising a frame and a power system mounted on the frame, the power system comprising at least a battery, an electric motor and a range extender system as described in any one of the above, the electric motor being connected to the battery and used to drive the extended-range vehicle, and the generator being connected to the battery and used to supply power to the battery.

[0028] In the present application, the generator and the engine are separated by a sealing end plate, the gap between the generator housing and the sealing end plate is sealed by a first seal, and the shaft connection position of the range extender system is sealed by a first oil seal and a second oil seal, thereby improving the sealing of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leaking to the outside through the gap between the engine and the generator, thereby improving the stability of the generator's heat dissipation effect, and further reducing the risk of thermal runaway of the generator, thereby reducing the risk of functional degradation or even failure of the generator, the range extender system and the extended-range vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0030] Figure 1 This is a connection diagram of the power system of an extended-range vehicle;

[0031] Figure 2 A schematic diagram of the structure of an engine and a generator in an embodiment of a range extender system before improvement;

[0032] Figure 3 A schematic diagram of the structure of an engine and a generator in another embodiment of a range extender system before improvement;

[0033] Figure 4 An exploded diagram of the range extender system provided in this application;

[0034] Figure 5 A cross-sectional view of the structure of the range extender system provided in this application in one embodiment;

[0035] Figure 6 for Figure 4 A structural cross-sectional view of a sealing end plate in one embodiment;

[0036] Figure 7 for Figure 5 A partial enlarged view of part I;

[0037] Figure 8for Figure 5 A partial enlarged view of part II;

[0038] Figure 9 for Figure 4 A structural cross-sectional view of a sealing end plate in one embodiment;

[0039] Figure 10 for Figure 4 A schematic structural diagram of a sealing end plate in one embodiment;

[0040] Figure 11 for Figure 10 Left view of;

[0041] Figure 12 for Figure 4 A schematic structural diagram of a cylinder block of an engine in one embodiment;

[0042] Figure 13 Cross-sectional view of the cylinder body and the sealing end plate at the first ventilation channel and the second ventilation channel

[0043] Figure 14 for Figure 12 An enlarged view of the local structure at the second ventilation channel.

[0044] Reference numerals:

[0045] 01-frame;

[0046] 02-wheel;

[0047] 1-Engine;

[0048] 11-cylinder body;

[0049] 111- second ventilation channel;

[0050] 112-Ontology;

[0051] 113-installation department;

[0052] 12-output crankshaft;

[0053] 13-flywheel;

[0054] 14-first cavity;

[0055] 15-Mounting hole;

[0056] 2- generator;

[0057] 21- housing;

[0058] 22- stator;

[0059] 23-rotor;

[0060] 24-opening;

[0061] 25-gap;

[0062] 3-Battery;

[0063] 4- Electric motor;

[0064] 5-Sealing end plate;

[0065] 51-Ontology part;

[0066] 511-First ontology;

[0067] 511A-channel;

[0068] 511B-Oil seal installation part;

[0069] 512-Second Body;

[0070] 513-second through hole;

[0071] 52-connecting portion;

[0072] 521-first through hole;

[0073] 53-first ventilation channel;

[0074] 6-first fastener;

[0075] 7- second fastener;

[0076] 8- third fastener;

[0077] 9- first sealing member;

[0078] 1A-first oil seal;

[0079] 1B-second oil seal;

[0080] 1C-Second cavity. DETAILED DESCRIPTION

[0081] In order to better understand the technical solution of the present application, the embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0082] It should be clear that the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0083] The terms used in the embodiments of the present application are for the purpose of describing specific embodiments only and are not intended to limit the present application. The singular forms "a", "an", "the" and "the" used in the embodiments of the present application and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise.

[0084] It should be understood that the term "and / or" as used herein simply describes a relationship between associated objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A alone, A and B together, or B alone. Furthermore, the character " / " in this document generally indicates an "or" relationship between the associated objects.

[0085] With the rapid development of the new energy vehicle industry, extended-range vehicles have become the technology route chosen by more and more car companies because they solve the range anxiety problem of pure electric vehicles and provide a completely pure electric driving experience.

[0086] Figure 1 This is a connection diagram of the power system of the extended-range vehicle, such as Figure 1 As shown, the body of the extended-range vehicle includes at least a frame 01 and wheels 02 mounted on the frame 01. The number of wheels 02 can be one, two or four. The power system of the extended-range vehicle is mounted on the frame 01. The power system includes at least an electric motor 4 connected to the wheel, a battery 3 connected to the electric motor 4, a generator 2 connected to the battery 3 and an electric motor 4 connected to the generator 2. The generator 2 and the engine 1 are combined to form the range extender system of the extended-range vehicle, which can charge the battery 3, thereby improving the endurance of the battery 3.

[0087] Figure 2 FIG. 1 is a schematic diagram of the structure of the engine 1 and the generator 2 in an embodiment of the range extender system. Figure 2 As shown, the engine 1 includes an output crankshaft 12, which can rotate around its own axis; the generator 2 includes a stator 22 and a rotor 23 arranged in a cavity surrounded by a housing 21, the stator 22 is sleeved on the outside of the rotor 23, and a resistance coil for connecting to the battery 3 is wound on the stator 22, and the output crankshaft 12 is connected to the rotor 23 through the flywheel 13. When the range extender system is working, the output crankshaft 12 of the engine 1 can drive the rotor 23 to rotate, so that the magnetic field generated by the rotor 23 changes. According to the principle of magnetoelectricity, an induced current is generated in the resistance coil on the stator 22, that is, the generator 2 can convert the mechanical energy generated by the engine 1 into electrical energy and store it in the battery 3, thereby charging the battery 3.

[0088] In order to ensure the normal and stable operation of the generator, the generator needs to be cooled to reduce the risk of damage due to excessive temperature. Normally, the cooling method of the generator can be oil cooling. The generator that uses oil cooling to dissipate heat is referred to as an oil-cooled motor. In an oil-cooled motor, there is cooling oil inside the generator. The cooling oil can flow through the heat-generating components such as the stator, rotor, and winding inside the generator and take away the heat to achieve cooling of the generator.

[0089] When the output crankshaft 12 is indirectly connected to the rotor 23, as shown in FIG. Figure 2 As shown, a flywheel 13 is provided on the output crankshaft 12, and the rotor 23 is connected to the flywheel 13 by a spline. This connection structure results in a larger overall size of the range extender system, which is not conducive to the development of the range extender system towards low cost, miniaturization and lightweight. In view of this, the range extender system can be set as a direct-connected range extender system, that is, the output crankshaft is directly connected to the rotor to reduce the overall size of the range extender system.

[0090] The structure of the direct-connect range extender system is as follows: Figure 3 As shown, the upper cover of the housing 21 of the generator 2 is removed, so that the inner cavity of the engine is opened and an opening 24 is formed, the internal stator 22 and rotor 23 are exposed at the opening 24, and the output crankshaft 12 extends into the housing 21 through the opening 24 and is directly connected to the rotor 23. The direct-connected range extender system has a smaller size. At this time, the housing 21 of the generator 2 cannot form a closed component. When the generator 2 is an oil-cooled motor, the cooling oil inside the generator 2 has a high risk of leakage at the opening 24 and the gap 25 between the housing 21 and the cylinder block 11 of the engine. The leakage of the cooling oil will cause the cooling effect of the generator 2 to deteriorate, the temperature to rise, and even the risk of failure. The leaked cooling oil also poses risks of environmental pollution and fire, which makes the application of oil-cooled motors a safety hazard.

[0091] In order to solve the sealing problem of the oil-cooled motor in the direct-connected range extender system, the embodiment of the present application provides a range extender system with better sealing effect. Figure 4 The exploded diagram of the range extender system provided in this application is as follows: Figure 4 As shown, the range extender system provided in the embodiment of the present application includes a generator 2, an engine 1 and a sealing end plate 5, wherein the generator 2 is an oil-cooled motor. Figure 5 is a cross-sectional view of the range extender system, as shown in Figure 5As shown, a sealing end plate 5 is located between the generator 2 and the engine 1 along the distribution direction X of the engine 1 and the generator 2. The generator 2 includes at least a housing 21, a stator 22 and a rotor 23. The stator 22 and the rotor 23 are both mounted on the housing 21 and located in the cavity surrounded by the housing 21. The engine 1 includes at least a cylinder block 11 and an output crankshaft 12. Along the distribution direction X of the engine 1 and the generator 2, one end of the output crankshaft 12 extends to the outside of the cylinder block 11 through a mounting hole on the cylinder block 11, and the other end is connected to the rotor 23. A channel 511A for the output crankshaft 12 to pass through is provided on the sealing end plate 5, that is, the output crankshaft 12 first passes through the channel 511A on the sealing end plate 5 and then is connected to the rotor 23. The sealing end plate 5 is used to seal the gap between the generator 2 and the engine 1.

[0092] In this embodiment, the sealing end plate 5 is used to seal the gap between the generator 2 and the engine 1. When the cooling oil in the cavity of the generator 2 splashes toward the engine 1, it can be blocked by the sealing end plate 5, thereby improving the sealing of the connection between the engine 1 and the generator 2, thereby reducing the risk of cooling oil in the cavity of the generator leaking through the gap between the cylinder 11 and the housing 21, reducing the safety hazards caused by cooling oil leakage, and thereby improving the stability of the heat dissipation effect of the generator, thereby reducing the risk of functional degradation or even failure of the generator, range extender system and range-extended vehicle due to high generator temperature.

[0093] Among them, the sealing end plate can be made of process materials such as stamped steel plate, die-cast aluminum, injection-molded non-metallic materials, etc. The embodiment of the present application does not specifically limit the material type of the sealing end plate.

[0094] Figure 6 This is a cross-sectional view of the structure of the sealing end plate 5 in one embodiment, as shown in FIG. Figure 6 As shown, the sealing end plate 5 includes a main body portion 51 and a connecting portion 52. Along the radial direction of the sealing end plate 5, the connecting portion 52 is located outside the main body portion 51. Figure 5 and Figure 6 The connecting portion 52 is clamped and fixed by the cylinder block 11 of the engine 1 and the housing 21 of the generator 2 to reduce the risk of the sealing end plate 5 being separated from the engine 1 and the generator 2, thereby improving the stability of the connection between the sealing end plate 5 and the engine 1 and the generator 2, and further facilitating the improvement of the sealing performance of the connection position between the engine 1 and the generator 2, and reducing the risk of the cooling oil in the generator cavity leaking through the connection position between the engine and the generator.

[0095] In one possible design, the sealing end plate 5 is directly clamped and fixed by the cylinder block of the engine and the casing of the generator to simplify the connection method between the sealing end plate 5 and the generator and the engine, which is conducive to reducing the size of the sealing end plate 5, the casing of the generator, and the cylinder block of the engine, and is also conducive to reducing the gap between the engine and the generator, thereby facilitating the miniaturization design of the range extender system.

[0096] In another possible design, such as Figure 5 As shown, the cylinder block 11 of the engine 1 and the housing 21 of the generator 2 are fixedly connected by a first fastener 6. The first fastener 6 includes but is not limited to screws, bolts, pins and other structures. The specific structure and type of the first fastener 6 are not particularly limited in this embodiment of the application. Figure 6 A first through hole 521 for the first fastener 6 to pass through is provided at the connecting portion 52, that is, one end of the first fastener 6 passes through the housing 21 of the generator 2 and the first through hole 521 on the sealing end plate 5 in sequence, and then extends into the cylinder body 11 of the engine 1 and is tightened and fixed.

[0097] In this embodiment, a portion of the first fastener 6 is located in the first through hole 521, and the first fastener 6 can limit the sealing end plate 5, thereby reducing the risk of deviation or even separation from the generator 2 and the engine 1 during the installation, transportation, and use of the range extender system, thereby further improving the connection stability between the sealing end plate 5 and the engine 1 and the generator 2, which is beneficial to improving the sealing of the connection position between the engine 1 and the generator 2, thereby reducing the risk of cooling oil leakage.

[0098] like Figure 6 As shown, the main body 51 includes a first body 511 and a second body 512, the second body 512 is located between the first body 511 and the connecting portion 52, one end of the second body 512 is connected to the connecting portion 52, and the other end of the second body 512 is connected to the first body 511, and the second body 512 is inclined along the distribution direction of the engine 1 and the generator 2, that is, the first body 511, the second body 512 and the connecting portion 52 form a trapezoidal structure, wherein the channel 511A for the output crankshaft 12 to pass through is located on the first body 511; in the distribution direction X of the engine 1 and the generator 2, the first body 511 abuts against the cylinder block 11, and the first body 511 and the cylinder block 11 are fixedly connected by the second fastener 7, that is, as shown Figure 6 As shown, a second through hole 513 is provided on the first body 511 , and one end of the second fastener 7 passes through the second through hole 513 and extends into the cylinder body 11 to be screwed and fixed.

[0099] In this embodiment, the connection portion 52 of the sealing end plate 5 is clamped between the cylinder block 11 of the engine 1 and the housing 21 of the generator 2. Simultaneously, the first body 511 abuts against the cylinder block 11 of the engine 1, reducing the risk of the forces exerted by the engine 1 and generator 2 on the sealing end plate 5 being concentrated entirely on the connection portion 52. This reduces the risk of damage to the connection portion 52 during operation of the range extender system and extends the service life of the sealing end plate 5. The first body 511 is fixedly connected to the cylinder block 11, further enhancing the stability of the connection between the sealing end plate 5 and the engine 1 and generator 2, thereby improving the sealing performance of the connection between the engine 1 and generator 2 and reducing the risk of cooling oil leakage.

[0100] Figure 7 This is a partial enlarged view of the connection position of the generator 2, the engine 1 and the sealing end plate 5, as shown in FIG. Figure 7 As shown, the range extender system also includes a first seal 9. Along the distribution direction X of the engine 1 and the generator 2, the first seal 9 is located between the sealing end plate 5 and the housing 21, and along the radial direction of the sealing end plate 5, the first seal 9 is located on the inner side of the cylinder body 11. Specifically, the first seal 9 is sleeved in the area between the first fastener 6 and the channel 511A, that is, the first seal 9 can reduce the risk of cooling oil inside the generator 2 entering the interior of the engine 1 through the gap between the housing 21 and the sealing end plate 5 and the first fastener 6, and reduces the risk of cooling oil inside the generator 2 overflowing to the outside through the gap between the housing 21 and the sealing end plate 5, thereby improving the sealing of the connection position between the engine 1 and the generator 2, thereby reducing the risk of cooling oil leakage.

[0101] Among them, the first sealing component can be a sealing strip, sealant, steel pad, silicone, etc. The embodiment of the present application does not specifically limit the specific material and structure of the first sealing component.

[0102] The range extender system provided in the embodiment of the present application is a direct-connected range extender system, that is, the output crankshaft is directly connected to the rotor. Figure 8 This is a partial enlarged view of the connection position of the generator 2, the engine 1 and the sealing end plate 5, as shown in FIG. Figure 8 As shown, the output crankshaft 12 and the rotor 23 are directly connected via a third fastener 8, eliminating the flywheel structure, thereby reducing the distance between the generator 2 and the engine 1. Along the distribution direction X of the engine 1 and the generator 2, the axial dimension of the range extender system is reduced, which is conducive to the development of low-cost, miniaturized, and lightweight range extenders. In this case, the stability of the range extender system can be improved by adding structures such as a dual-clutch transmission and a planetary gear set.

[0103] In any of the above embodiments, Figure 8As shown, the range extender system also includes a second seal, a first oil seal 1A. This second seal can be a common commercially available oil seal structure, and the specific structure of first oil seal 1A is not described here. First oil seal 1A is located within bore 511A of sealing end plate 5. Along the radial direction of sealing end plate 5, one side of first oil seal 1A abuts the sidewall of bore 511A, and the other side of first oil seal 1A abuts the output crankshaft 12.

[0104] In this embodiment, the first oil seal 1A is capable of sealing the gap between the output crankshaft 12 and the sealing end plate 5, thereby reducing the risk of cooling oil within the generator 2 entering the outside world or the engine 1 through the gap between the output crankshaft 12 and the sealing end plate 5, thereby improving the sealing performance of the connection between the engine 1 and the generator 2. In addition, during the rotation of the output crankshaft 12, the temperature of the output crankshaft 12 and the first oil seal 1A increases due to friction. Since the first oil seal 1A has good thermal conductivity, it is able to conduct the heat generated by the friction between the output crankshaft 12 and the first oil seal 1A to the housing 21, the sealing end plate 5, and the air. The gap between the output crankshaft 12 and the sealing end plate 5 is sealed by the first oil seal 1A, thereby reducing the risk of the second seal being damaged by high temperature due to the rotational friction of the output crankshaft 12, thereby extending the service life of the second seal.

[0105] Figure 9 The structural cross-sectional view of the sealing end plate 5 in one embodiment is shown. The first body 511 includes an oil seal mounting portion 511B. The oil seal mounting portion 511B extends along the distribution direction X of the engine 1 and the generator 2 toward the housing 21. The oil seal mounting portion 511B encloses a channel 511A. Figure 8 In the radial direction of the sealing end plate 5 , the first oil seal 1A abuts against the oil seal mounting portion 511B.

[0106] In this embodiment, when the thickness of the sealing end plate 5 is relatively small, an oil seal mounting portion 511B extending along the distribution direction of the engine and the generator is provided, which can increase the length of the channel 511A, so that the length of the channel 511A meets the installation dimension requirement of the first oil seal 1A, thereby reducing the risk of difficulty or even inability to install the first oil seal 1A due to the small length of the channel 511A. In addition, on the premise that the length of the channel 511A meets the installation dimension requirement of the first oil seal 1A, the thickness of the edge position of the sealing end plate 5 can also be reduced, thereby helping to reduce the overall weight of the sealing end plate 5 and the range extender system.

[0107] Reference again Figure 8The engine is provided with a second oil seal 1B. The second oil seal 1B is a common oil seal structure on the market. The specific structure of the second oil seal 1B is not described here. Along the radial direction of the output crankshaft 12, that is, along the distribution direction X of the engine 1 and the generator 2, the second oil seal 1B is located between the output crankshaft 12 and the cylinder block 11. At least a portion of the second oil seal 1B is located in the mounting hole 15. One side of the second oil seal 1B abuts against the cylinder block 11, and the other side of the second oil seal 1B abuts against the output crankshaft 12.

[0108] Since the second oil seal can seal the gap between the output crankshaft and the cylinder body, and the first oil seal can seal the gap between the output crankshaft and the sealing end plate, during the operation of the range extender system, there is a high risk of a pressure difference between the cavity between the first oil seal and the second oil seal and the outside world. Along the distribution direction X of the engine and generator, if there is a pressure difference on both sides of the first oil seal and the second oil seal, the first oil seal and the second oil seal are very likely to deform and fail under the action of the pressure difference. In order to solve this problem, Figure 10 As shown, Figure 10 The sealing end plate 5 is a schematic structural diagram of an embodiment. The sealing end plate 5 is provided with a first ventilation channel 53 extending along its radial direction. The number of the first ventilation channel 53 is one, or as shown in FIG. Figure 11 As shown, Figure 11 The left side view of the sealing end plate 5 shows that a plurality of first ventilation channels 53 are arranged along the circumference of the sealing end plate 5. Figure 12 As shown, Figure 12 1 is a schematic structural diagram of a cylinder block 11 of an engine 1 in an embodiment. At least one second ventilation channel 111 is provided on the cylinder block 11 .

[0109] Figure 13 is a cross-sectional view of the cylinder body and the sealing end plate at the first ventilation channel and the second ventilation channel, as shown in FIG. Figure 13 As shown, the cylinder body 11 and the sealing end plate 5 form a first cavity 14, and the first oil seal 1A, the second oil seal 1B, the sealing end plate, the cylinder body and the output crankshaft form a second cavity 1C. In this embodiment, the second cavity 1C is connected to the first cavity 14 through the first ventilation channel 53, and the first cavity 14 is connected to the outside through the second ventilation channel 111, so that the second cavity is connected to the outside through the first ventilation channel, the first cavity and the second ventilation channel to balance the pressure on both sides of the first oil seal 1A and the second oil seal 1B, thereby reducing the deformation and failure of the first oil seal 1A and the second oil seal 1B under the action of the pressure difference, and improving the sealing between the cylinder body 11 and the output crankshaft 12.

[0110] In this embodiment, the second ventilation channel is provided at the radial edge of the cylinder body. Figure 12As shown, the cylinder body 11 includes a main body 112 and a mounting portion 113. The mounting portion 113 is located on the outer periphery of the main body 112. The main body 112 and the sealing end plate form the above-mentioned first cavity. The above-mentioned mounting hole 15 for the output crankshaft to pass through is provided on the main body 112, and the mounting portion 113 is connected to the shell. The second ventilation channel 111 is provided on the mounting portion 113 and radially passes through the mounting portion 113, thereby connecting the first cavity with the outside world. The second ventilation channel 111 is provided on the mounting portion 113 for connection with the shell 21, so that the shell 21 can block a portion of the second ventilation channel 111, thereby reducing the area of the second ventilation channel 111 exposed to the outside world, thereby reducing the risk of external liquid entering the interior of the range extender system through the second ventilation channel 111.

[0111] like Figure 13 As shown, the first ventilation channel is provided on a side surface of the sealing end plate facing the cylinder body, so that the first ventilation channel is communicated with the first cavity.

[0112] In other embodiments, the first ventilation channel may be directly connected to the second ventilation channel, so that the second cavity is in communication with the outside through the first ventilation channel and the second ventilation channel.

[0113] Figure 13 is an enlarged view of the local structure of the second ventilation channel 111. In another embodiment, as Figure 13 As shown, the contour shape of the second ventilation channel 111 is S-shaped, Z-shaped or other bent shapes, that is, when there is condensed water, rainwater or other liquids outside the cylinder body 11, the side wall of the second ventilation channel 111 can block at least part of the liquid, thereby reducing the risk of external liquid entering the engine 1 through the second ventilation channel 111, and also reducing the risk of external liquid entering between the cylinder body 11 and the sealing end plate 5 through the second ventilation channel 111 and the first ventilation channel 53, thereby reducing the risk of external liquid entering the generator 2 through the gap between the sealing end plate 5 and the shell 21, thereby improving the waterproof performance of the range extender system; in addition, when the range extender system is installed and fixed on the vehicle frame, the second ventilation channel is located at the lower end of the cylinder body. When condensed water exists between the cylinder body and the sealing end plate, the condensed water can enter the second ventilation channel and flow along the side wall of the second ventilation channel under the action of gravity until it is discharged to the outside, thereby reducing the accumulation of condensed water inside the range extender system.

[0114] The number of the second ventilation channels can be one or more, as long as they can connect the cavity with the outside world. The embodiment of the present application does not specifically limit the specific number of the first ventilation channels. In the embodiment of the present application, the number of the second ventilation channel is one.

[0115] In summary, reference Figure 4 The installation process of the range extender system provided in this application is as follows:

[0116] Press and fix the first oil seal 1A onto the hole 511A of the sealing end plate 5;

[0117] The sealing end plate 5 is fixed to the cylinder block 11 of the engine by means of a second fastener;

[0118] The rotor 23 of the generator is mounted on the output crankshaft 12 of the engine;

[0119] Install the first sealing member 9 on the sealing end plate 5;

[0120] The housing 21 of the generator is mounted on the engine cylinder block 11 through a circle of flange bolts, so that the sealing end plate 5 and the first sealing member 9 are clamped and fixed by the housing 21 and the cylinder block 11 .

[0121] In this embodiment, the generator and the engine are separated by a sealing end plate, the gap between the generator housing and the sealing end plate is sealed by a first seal, and the shaft connection position of the range extender system is sealed by a first oil seal and a second oil seal, thereby improving the sealing of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leaking to the outside through the gap between the engine and the generator, thereby improving the stability of the heat dissipation effect of the generator, and further reducing the risk of functional degradation or even failure of the generator, the range extender system and the extended-range vehicle due to high generator temperature.

[0122] The same and similar parts between the various embodiments in this specification can be referenced to each other.

Claims

1. A range extender system, characterized in that: The range extender system includes: A generator, the generator comprising at least a housing, a stator and a rotor, wherein the stator and the rotor are both mounted on the housing and located in a cavity enclosed by the housing; An engine, the engine comprising at least a cylinder block and an output crankshaft, the cylinder block being connected to the housing, one end of the output crankshaft extending out of the cylinder block through a mounting hole of the cylinder block along the distribution direction of the engine and the generator, and the other end being directly connected to the rotor; A sealing end plate is provided on the sealing end plate with a channel for the output crankshaft to pass through. Along the distribution direction of the engine and the generator, the sealing end plate is located between the engine and the generator, and the sealing end plate is used to seal the gap between the generator and the engine.

2. The range extender system according to claim 1, characterized in that: The sealing end plate includes a main body portion and a connecting portion. Along the radial direction of the sealing end plate, the connecting portion is located outside the main body portion and is clamped by the housing and the cylinder body.

3. The range extender system according to claim 2, characterized in that: The housing and the cylinder are fixedly connected via a first fastener, and a first through hole for the first fastener to pass through is provided at the connecting portion.

4. The range extender system according to claim 2, characterized in that: The main body includes a first body and a second body, the second body is located between the first body and the connecting portion, one end of the second body is connected to the connecting portion, and the other end of the second body is connected to the first body, the second body is inclined along the distribution direction of the engine and the generator, and the channel is located on the first body; In the distribution direction of the engine and the generator, the first body abuts against the cylinder and is fixedly connected by a second fastener.

5. The range extender system according to any one of claims 2 to 4, characterized in that: The range extender system further includes a first seal located between the sealing end plate and the housing, and the first seal is located inside the cylinder.

6. The range extender system according to any one of claims 2 to 4, characterized in that: The range extender system further includes a first oil seal, which is located in the hole. Along the radial direction of the sealing end plate, one side of the first oil seal abuts against the side wall of the hole, and the other side of the first oil seal abuts against the output crankshaft.

7. The range extender system according to claim 6, characterized in that: The main body comprises a first body and a second body, the second body is located between the first body and the connecting portion, one end of the second body is connected to the connecting portion, and the other end of the second body is connected to the first body; The first body includes an oil seal mounting portion, which extends toward the housing along the distribution direction of the engine and the generator. The oil seal mounting portion encloses the channel, and along the radial direction of the sealing end plate, the first oil seal abuts against the oil seal mounting portion.

8. The range extender system according to claim 6, characterized in that: The engine includes a second oil seal, at least a portion of which is located in the mounting hole, and along the radial direction of the output crankshaft, one side of the second oil seal abuts against the cylinder block, and the other side of the second oil seal abuts against the output crankshaft; The cylinder body and the sealing end plate form a first cavity, and a second cavity is provided between the first oil seal and the second oil seal; The sealing end plate is provided with a first ventilation channel, and the second cavity is connected to the first cavity through the first ventilation channel. The cylinder body is provided with a second ventilation channel, and the first cavity is connected to the outside through the second ventilation channel.

9. The range extender system according to claim 8, characterized in that: The first ventilation channel is provided on a side of the sealing end plate facing the cylinder body; The cylinder body includes a main body and a mounting portion, the mounting portion is located on the outer periphery of the main body, the mounting portion and the sealing end plate form the first cavity, the mounting portion is connected to the shell, and the second ventilation channel is provided in the mounting portion and passes through the mounting portion along the radial direction of the cylinder body.

10. The range extender system according to claim 9, characterized in that: The second ventilation channel has a curved outline.

11. An extended-range vehicle, characterized in that: The extended-range vehicle includes: Frame; A power system installed on the vehicle frame, the power system comprising at least a battery, an electric motor and a range extender system according to any one of claims 1 to 10, the electric motor being connected to the battery and used to drive the extended-range vehicle, and the generator being connected to the battery and used to supply power to the battery.

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