Range-extended generator system and automobile

Abstract

The utility model discloses a range-extended generator system and an automobile, and relates to the technical field of vehicle-mounted generators, the range-extended generator system comprises a housing, a stator, a rotor, a flange plate and a controller, and a mounting cavity is formed in the housing; the stator is arranged in the mounting cavity, and the outer periphery of the stator is connected to the inner wall of the shell; the rotor and the stator are coaxially arranged and located on the inner edge of the stator, and a gap is formed between the outer circumferential wall of the rotor and the inner circumferential wall of the stator. A positioning spigot is formed in the flange plate to sleeve an engine crankshaft, and the rotor sleeves the outer edge of the flange plate; the controller is connected to the end, away from the flange plate, of the shell. The shell is connected with the controller through bolts. According to the scheme, the rotor is connected to the flange plate, the flange plate is connected and fixed to the engine crankshaft through the positioning spigot, positioning and fixing of the rotor are achieved without bearing supporting, two originally independent assemblies of the generator and the controller are integrated together, a cover body is saved, and the weight and the size of the range-extending type generator system are reduced.

Description

Technical Field

[0001] This utility model relates to the field of vehicle-mounted generator technology, and in particular to a range-extended generator system and a vehicle. Background Technology

[0002] The current state of the vehicle-mounted range-extender generator system industry is characterized by a significant increase in market size and intense market competition. With the continuous advancement of electric vehicle manufacturing technology and increasing market demand, the market size of vehicle-mounted range-extender generator systems is showing a rapid growth trend. At the same time, market competition is becoming increasingly fierce, involving multiple industries such as generator manufacturing and electric vehicle manufacturing. Many well-known generator manufacturers both domestically and internationally have invested in the production and sales of vehicle-mounted range-extender generator systems.

[0003] Despite the significant progress made in the range-extended generator system industry, there are still some drawbacks and problems. The existing range-extended generator systems have relatively complex structures, resulting in higher product weight and costs, which means that consumers have to bear higher costs when purchasing them. Utility Model Content

[0004] The main purpose of this invention is to propose a range-extended generator system and vehicle, which aims to simplify the structure of the range-extended generator system and reduce its production cost.

[0005] To achieve the above objectives, the range-extended generator system proposed in this utility model includes:

[0006] A housing having an installation cavity formed within it;

[0007] The stator is disposed within the mounting cavity, and the outer periphery of the stator is connected to the inner wall of the housing;

[0008] The rotor is coaxially arranged with the stator and located on the inner edge of the stator, and a gap is formed between the outer peripheral wall of the rotor and the inner peripheral wall of the stator.

[0009] A flange having a locating stop for fitting onto an engine crankshaft, and a rotor fitted onto the outer edge of the flange;

[0010] A controller is connected to the end of the housing away from the flange, and the housing and the controller are bolted together.

[0011] In one embodiment, the flange has a plurality of fixing holes, each of which is evenly distributed along the circumference of the positioning stop, and the fixing holes are used to pass bolts to connect the flange to the engine crankshaft.

[0012] In one embodiment, a heat dissipation groove is formed on the outer periphery of the stator, and the heat dissipation groove and the inner wall of the housing form a cooling water channel. The controller is provided with a water inlet, and the housing is provided with a water outlet. The water inlet and the water outlet are respectively connected to the cooling water channel and form a cooling circuit.

[0013] In one embodiment, the heat dissipation groove includes a first annular groove, a second annular groove, and a connecting groove. The first annular groove and the second annular groove are both arranged along the circumference of the stator and are respectively located at both ends of the stator axial direction. The two ends of the connecting groove in the extension direction are respectively connected to the first annular groove and the second annular groove. The water inlet end is connected to the first annular groove, and the water outlet end is connected to the second annular groove.

[0014] In one embodiment, the connecting grooves include a plurality of grooves, and the connecting grooves are distributed at intervals along the circumference of the stator.

[0015] In one embodiment, the outer periphery of the stator is coated with a waterproof and thermally conductive adhesive.

[0016] In one embodiment, a connecting harness is provided at one end of the housing near the controller, and the connecting harness is connected to the controller using bolts and connectors.

[0017] This utility model also proposes a vehicle, the vehicle including a range-extender generator system, the range-extender generator system comprising:

[0018] A housing having an installation cavity formed within it;

[0019] The stator is disposed within the mounting cavity, and the outer periphery of the stator is connected to the inner wall of the housing;

[0020] The rotor is coaxially arranged with the stator and located on the inner edge of the stator, and a gap is formed between the outer peripheral wall of the rotor and the inner peripheral wall of the stator.

[0021] A flange having a locating stop for fitting onto an engine crankshaft, and a rotor fitted onto the outer edge of the flange;

[0022] A controller is connected to the end of the housing away from the flange, and the housing and the controller are bolted together.

[0023] The present invention proposes a range-extended generator system, comprising a housing, a stator, a rotor, and a flange. By providing a flange to the rotor and connecting and fixing the flange to the engine crankshaft through a positioning stop, the rotor itself does not require bearing support, thus achieving rotor positioning and fixation. This simplifies the structure of the range-extended generator system and avoids shaft current problems. Furthermore, by integrating the generator and controller, which were originally two independent components, into one, the overall structure of the range-extended generator system is simplified, a cover is saved, and the overall weight and volume of the range-extended generator system are reduced. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0025] Figure 1 A front view of an embodiment of the range-extended generator system provided by this utility model;

[0026] Figure 2 for Figure 1 Cross-sectional view of a medium-range extended generator system;

[0027] Figure 3 for Figure 1 Exploded structural diagram of a medium-range extended generator system;

[0028] Figure 4 This is a schematic diagram of the flange of the range-extended generator system of this utility model;

[0029] Figure 5 for Figure 2 A schematic diagram of the middle stator.

[0030] Explanation of icon numbers:

[0031] 1000. Range-extended generator system; 1. Housing; 11. Water outlet; 12. Connecting harness; 2. Stator; 21. Heat dissipation groove; 211. First annular groove; 212. Second annular groove; 213. Connecting groove; 3. Rotor; 4. Flange; 41. Positioning stop; 42. Fixing hole; 5. Controller; 51. Water inlet.

[0032] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0034] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0035] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0036] The current state of the vehicle-mounted range-extender generator system industry is characterized by a significant increase in market size and intense market competition. With the continuous advancement of electric vehicle manufacturing technology and increasing market demand, the market size of vehicle-mounted range-extender generator systems is showing a rapid growth trend. At the same time, market competition is becoming increasingly fierce, involving multiple industries such as generator manufacturing and electric vehicle manufacturing. Many well-known generator manufacturers both domestically and internationally have invested in the production and sales of vehicle-mounted range-extender generator systems.

[0037] Despite the significant progress made in the range-extended generator system industry, there are still some drawbacks and problems. The existing range-extended generator systems have relatively complex structures, resulting in higher product weight and costs, which means that consumers have to bear higher costs when purchasing them.

[0038] To solve the above problems, please refer to... Figures 1 to 5This utility model proposes a range-extended generator system 1000, including a housing 1, a stator 2, a rotor 3, a flange 4, and a controller 5. The housing 1 has an installation cavity; the stator 2 is disposed in the installation cavity, and the outer periphery of the stator 2 is connected to the inner wall of the housing 1; the rotor 3 is coaxially arranged with the stator 2 and located on the inner edge of the stator 2, and a gap is formed between the outer periphery of the rotor 3 and the inner periphery of the stator 2; the flange 4 has a positioning stop 41, which is used to fit onto the engine crankshaft, and the rotor 3 is fitted onto the outer edge of the flange 4; the controller 5 is connected to the end of the housing 1 away from the flange 4, and the housing 1 and the controller 5 are connected by bolts.

[0039] This utility model proposes a range-extended generator system 1000, including a housing 1, a stator 2, a rotor 3, and a flange 4. By connecting the rotor 3 to the flange 4 and fixing the flange 4 to the engine crankshaft via a positioning stop 41, the rotor 3 itself does not require bearing support, thus achieving positioning and fixation of the rotor 3. This simplifies the structure of the range-extended generator system 1000 and avoids shaft current problems. Furthermore, the controller 5 is connected to the side of the housing 1 facing away from the flange 4, and the two are tightly connected via a mounting surface and secured with bolts or other fasteners. Integrating the generator and controller 5, originally two independent components, simplifies the overall structure of the range-extended generator system 1000, saves a cover, and reduces the overall weight and volume of the range-extended generator system 1000. In addition, the controller 5 is designed to be separate from the housing 1 and connected by bolts, which helps simplify the assembly and subsequent maintenance of the range-extended generator system 1000. The independent design of controller 5 allows it to be upgraded or replaced according to different needs without replacing the entire range extender generator system 1000, which improves the system's flexibility and scalability. The design of controller 5 away from flange 4 helps reduce the heat load on controller 5, thereby improving its reliability and lifespan.

[0040] In an optional embodiment, to further improve the connection stability between flange 4 and engine crankshaft, please refer to... Figures 2 to 4The flange 4 has multiple fixing holes 42, which are evenly distributed around the circumference of the locating stop 41. These fixing holes 42 are used to pass bolts to connect the flange 4 to the engine crankshaft. This design provides a simple and effective connection method, allowing the flange 4 to be securely connected to the engine crankshaft, ensuring power transmission between the rotor 3 and the engine. Furthermore, by providing multiple fixing holes 42 on the flange 4, the stability of the connection is increased, and bolts can be installed in different positions to accommodate different installation requirements. This design also helps to distribute stress at the connection point, reducing fatigue damage that may occur due to a single bolt connection. The evenly distributed fixing holes 42 also help the flange 4 maintain a uniform stress distribution under load, thereby improving the reliability and durability of the entire range extender generator system 1000 structure. In addition, multiple weight-reduction holes are provided around the periphery of the flange 4, minimizing its weight while ensuring its strength, which helps to reduce the weight and cost of the range extender generator system 1000.

[0041] Furthermore, the range-extended generator system 1000 in this embodiment employs resolver soft decoding to achieve decoding of the controller 5. The controller 5 is designed with an excitation circuit and a sampling circuit. First, the excitation circuit generates a high-frequency excitation signal. Then, based on the position of the rotor 3, the return winding will induce a corresponding voltage signal. The voltage signal induced by the return winding is processed by the sampling circuit and converted into a digital signal. The digital signal is processed and identified by the controller 5 to obtain the position of the rotor 3, and precise control is achieved through the position of the rotor 3. This eliminates the need for a dedicated decoding chip, simplifying the decoding process of the controller 5.

[0042] Furthermore, a connecting harness 12 is provided at the end of the housing 1 near the controller 5. The connecting harness 12 is connected to the controller 5 using bolts and connectors. This design simplifies the electrical connection between the generator and the controller 5. By using the connecting harness 12 to achieve the electrical connection between the housing 1 and the controller 5, electrical connection and disconnection can be easily performed. The connecting harness 12, hidden between the housing 1 and the controller 5, eliminates external wiring, simplifies the electrical structure of the range-extended generator system 1000, and improves its aesthetics. It also facilitates the assembly and disassembly of the range-extended generator system 1000 and facilitates subsequent maintenance. In addition, the wiring harness connection between the housing 1 and the controller 5 via plug-in connection, and further secured with bolts, provides a robust connection method that can withstand the vibration and stress generated during the operation of the range-extended generator system 1000, ensuring the stability and reliability of the electrical connection. This design also helps to reduce contact resistance at the electrical connection, thereby improving electrical efficiency.

[0043] In an optional embodiment, to improve the heat dissipation of the range-extended generator system 1000, please refer to... Figure 2 , Figure 3 as well as Figure 5 The stator 2 has heat dissipation grooves 21 formed on its outer periphery. The heat dissipation grooves 21 and the inner wall of the housing 1 form a cooling water channel. The controller 5 has a water inlet 51, and the housing 1 has a water outlet 11. The water inlet 51 and the water outlet 11 are respectively connected to the cooling water channel and form a cooling circuit. The design of the heat dissipation grooves 21 facilitates machining. By setting the cooling water channel inside the range-extended generator system 1000, the heat problem generated by the range-extended generator system 1000 during operation is effectively solved. The hidden design also simplifies the cooling mode of the range-extended generator system 1000, eliminating the need for additional external cooling pipes. This improves the cooling effect, and the hidden design also prevents damage and extends the service life of the cooling water channel. In addition, compared with the original separate generator and controller, the cooling water first flows into the controller to cool it, then flows out of the controller and then into the generator to cool it, and finally flows out of the generator, realizing the circulation of cooling water. In other words, the original separate controller and generator design required separate inlets and outlets for cooling water circulation. However, in this solution, by integrating the generator and controller into a single range-extended generator system 1000, only one inlet 51 on the controller 5 and one outlet 11 on the housing 1 are needed for cooling water circulation, simplifying the cooling pipe structure. The water flow removes heat, preventing overheating of the range-extended generator system 1000, thus ensuring stable operation and extending its service life. Furthermore, the cooling water channel design also helps improve the efficiency of the range-extended generator system 1000. The inlet 51 and outlet 11 allow for cooling water recycling, improving cooling efficiency and reducing water consumption.

[0044] Furthermore, the heat dissipation groove 21 includes a first annular groove 211, a second annular groove 212, and a connecting groove 213. The first annular groove 211 and the second annular groove 212 are both arranged circumferentially along the stator 2 and are located at both ends of the stator 2's axial direction. The two ends of the connecting groove 213 extend in the same direction and connect to the first annular groove 211 and the second annular groove 212, respectively. The water inlet end 51 connects to the first annular groove 211, and the water outlet end 11 connects to the second annular groove 212. This structural design allows cooling water to circulate between the two ends of the stator 2, effectively transferring heat from the stator 2 to the cooling water, thereby achieving efficient heat exchange. By dividing the heat dissipation groove 21 into two annular grooves and a connecting groove 213, the surface area of ​​contact between the cooling water and the stator 2 can be increased, improving heat exchange efficiency. In addition, this design helps to balance the temperature at both ends of the stator 2, reducing thermal stress caused by temperature differences, thereby improving the structural stability and durability of the stator 2.

[0045] Furthermore, the connecting grooves 213 include multiple grooves, each groove 213 being distributed at intervals along the circumference of the stator 2. This design makes the distribution of cooling water channels around the stator 2 more uniform, contributing to a more uniform cooling effect. By setting multiple spaced connecting grooves 213 around the stator 2, it can be ensured that the flow of cooling water around the stator 2 is more uniform, thereby improving the overall cooling efficiency of the stator 2. This helps reduce the risk of local overheating, allowing cooling water to reach every part of the stator 2 more effectively. In addition, the uniformly distributed connecting grooves 213 also help reduce the pressure loss of the cooling water channels, thereby improving the efficiency of the cooling system. In other optional embodiments, multiple first annular grooves 211 and second annular grooves 212 can also be provided, and the connecting grooves 213 can also be arranged at an angle to the axial direction along the outer periphery of the stator 2. Furthermore, the cross-sectional shape of the heat dissipation groove 21 can be rectangular, arc-shaped, or other structures, which can be selected according to actual needs and processing difficulty.

[0046] In an optional embodiment, to improve the waterproofing of the stator 2 and prevent cooling water from seeping into its interior, the outer periphery of the stator 2 is coated with a waterproof thermally conductive adhesive. Applying this adhesive improves the heat transfer efficiency between the stator 2 and the cooling water channels because it fills the tiny gaps between the stator 2 and the housing 1, reducing thermal resistance. Furthermore, the adhesive also provides waterproofing, preventing cooling water from seeping into the range-extended generator system 1000 and protecting the internal circuitry from moisture corrosion. The adhesive can also absorb thermal expansion and contraction to some extent, helping to reduce thermal stress caused by temperature changes, thereby protecting the structural integrity of the stator 2.

[0047] This utility model also proposes a vehicle including a range-extender generator system 1000. The specific structure of the range-extender generator system 1000 is as described in the above embodiments. By integrating the range-extender generator system 1000 into the vehicle, the energy efficiency of the vehicle can be improved, especially in hybrid or electric vehicles. The range-extender generator system 1000 can continuously generate electricity while the vehicle is in motion to charge the battery, thereby extending the vehicle's driving range. Furthermore, this design helps reduce the vehicle's dependence on external charging facilities, improving the vehicle's autonomy and flexibility. The compact design of the range-extender generator system 1000 also allows it to be easily integrated into the existing structure of the vehicle without negatively impacting the vehicle's performance or space. In addition, the lightweight integrated design of the range-extender generator system 1000 also helps reduce the vehicle's energy consumption and increase its driving range. Since this vehicle adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0048] The above description is merely an exemplary embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural transformations made based on the technical concept of the present utility model and the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A range-extended generator system, characterized in that, include: A housing having an installation cavity formed within it; The stator is disposed within the mounting cavity, and the outer periphery of the stator is connected to the inner wall of the housing; The rotor is coaxially arranged with the stator and located on the inner edge of the stator, and a gap is formed between the outer peripheral wall of the rotor and the inner peripheral wall of the stator. A flange having a locating stop for fitting onto an engine crankshaft, and a rotor fitted onto the outer edge of the flange; A controller is connected to the end of the housing away from the flange, and the housing and the controller are bolted together.

2. The range-extended generator system as described in claim 1, characterized in that, The flange has multiple fixing holes, which are evenly distributed around the circumference of the positioning stop. The fixing holes are used to insert bolts to connect the flange to the engine crankshaft.

3. The range-extended generator system as described in claim 2, characterized in that, The stator has a heat dissipation groove formed on its outer periphery. The heat dissipation groove and the inner wall of the housing form a cooling water channel. The controller has a water inlet end and the housing has a water outlet end. The water inlet end and the water outlet end are respectively connected to the cooling water channel and form a cooling circuit.

4. The range-extended generator system as described in claim 3, characterized in that, The heat dissipation groove includes a first annular groove, a second annular groove, and a connecting groove. The first annular groove and the second annular groove are both arranged along the circumference of the stator and are respectively located at both ends of the stator axial direction. The two ends of the connecting groove in the extension direction are respectively connected to the first annular groove and the second annular groove. The water inlet end is connected to the first annular groove, and the water outlet end is connected to the second annular groove.

5. The range-extended generator system as described in claim 4, characterized in that, The connecting grooves include multiple grooves, and each connecting groove is distributed at intervals along the circumference of the stator.

6. The range-extended generator system as described in claim 4, characterized in that, The outer periphery of the stator is coated with waterproof and thermally conductive adhesive.

7. The range-extended generator system as described in any one of claims 3 to 6, characterized in that, The housing is provided with a connecting harness at one end near the controller, and the connecting harness is connected to the controller by bolts and connectors.

8. A car, characterized in that, Includes the range-extended generator system as described in any one of claims 1 to 7.

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