All-in-one highly-integrated crankshaft direct-connection range-extending power system architecture

Abstract

The utility model discloses an all-in-one highly-integrated crankshaft direct-connection range-extending power system framework, and belongs to the technical field of range extender assemblies for new energy automobiles. The motor control unit is installed on the motor rear end cover, the control unit mainboard is installed between the motor control unit and the motor rear end cover, the mechanical oil pump is assembled in the motor rear end cover and connected with an oil inlet of the motor rotor and a cooling oil pipe, the motor stator is fixed in the motor shell, and the motor rotor is connected with a crankshaft in the motor shell. And the cooling oil pipe is arranged in the motor shell and can spray the motor stator. Compared with a traditional motor, the integrated crankshaft direct connection motor can achieve simultaneous demolding of the motor shell, an engine cylinder body and an engine oil pan, and has the advantages in the aspects of assembly technology, strength and the like; as the connection form is crankshaft direct connection, the overall axial length of the motor is shorter, and the motor can be adapted to more engine rooms of the whole vehicle; and fewer materials are used, and the cost is lower.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of the range extender assembly for new energy vehicles, and particularly relates to a multi-in-one high integration type crankshaft direct connection range extending power system architecture. BACKGROUND

[0002] The traditional range extender assembly is usually composed of an independent engine assembly, a range extending motor and an electronic control system, and the two systems exist and are produced independently without deep integration, which is not conducive to reducing the cost and structure size of the range extender assembly and does not meet the demand of the new energy vehicle market for miniaturization, high integration, low cost and high efficiency of the new energy power system.

[0003] The traditional range extending motor and electronic control system scheme for the new energy market are in the state of independent shell with crankshaft direct connection water cooling and non-crankshaft direct connection water or oil cooling, and the engine, motor and electronic control system need to be developed, designed and produced respectively without deep multi-in-one integration. The key matching parts such as the cylinder body, oil pan, motor and electronic control system are connected through different means according to different architectures. The non-direct connection range extending motor and electronic control system scheme needs to form a self-sealing to prevent the splashing of the cooling liquid; meanwhile, a front end connecting shell is designed, which increases the structure size, is not conducive to space arrangement, and uses more materials and increases the cost. The direct connection range extending motor and electronic control system scheme cancels the front end connecting shell, but the connection side with the engine needs to be sealed by glue, which requires high precision and increases the machining cost of the cylinder body and oil pan. The problems of the traditional range extender assembly structure, such as the machining, development of mold and construction of assembly line of the engine, range extending motor and electronic control system respectively, high machining size precision and high assembly precision, need to be solved, so the new range extender assembly crankshaft direct connection architecture is developed. SUMMARY

[0004] The utility model aims at providing a multi-in-one high integration type crankshaft direct connection range extending power system architecture to solve the above problems.

[0005] The utility model adopts the technical scheme of:

[0006] A multi-in-one high integration type crankshaft direct connection range extending power system architecture, comprising a motor control unit, a control unit mainboard, a mechanical oil pump, a motor rear end cover, a cooling oil pipe, a motor stator, a motor rotor and a motor shell; the motor control unit is installed on the motor rear end cover, the control unit mainboard is installed between the motor control unit and the motor rear end cover, the mechanical oil pump is assembled in the motor rear end cover, the mechanical oil pump is connected with the oil inlet of the motor rotor and the cooling oil pipe, the motor stator is fixed in the motor shell, the motor rotor is connected with the crankshaft in the motor shell, and the cooling oil pipe is arranged in the motor shell and can spray the motor stator.

[0007] Compared with the prior art, the utility model has the following beneficial effects:

[0008] 1、The integrated crankshaft direct connection motor of the utility model can realize the die forming of the motor shell, engine cylinder body and oil pan together, has advantages in assembly process, strength and the like; because of the crankshaft direct connection, the overall axial length of the motor is shorter, more vehicle cabins can be adapted; less material is used, and the cost is lower.

[0009] 2、When the traditional range extender is assembled, the motor shell, engine cylinder body and oil pan are assembled independently. After the cylinder body and oil pan are assembled, the rear end face formed by the cylinder body and oil pan has certain requirements for the pin hole machining precision when the motor is assembled, and meanwhile, the failure points are increased. When the pin hole or pin hole machining size is out of tolerance, the motor cannot be assembled. After the oil pan is assembled with the cylinder body, an inevitable step difference is formed on the rear end face of the engine. When the motor is assembled, the step difference causes the radial deviation of the motor, and affects the motor air gap.

[0010] The utility model changes the motor shell into an engine cylinder body and an oil pan integrated scheme. The motor shell can be machined and formed together with the engine cylinder body and the oil pan, and the two parts of the cylinder body integrated motor upper shell and the oil pan integrated motor lower shell are formed. The motor shell does not need to be fixed by installing screws, and the high-precision machining pin hole is cancelled, and the cost of the tool and the lathe is reduced. This assembly form forms a rear end face at the end of the motor shell, which is used for installing the motor rear end cover and the subsequent controller. The motor itself does not deviate radially, and does not affect the motor stator and rotor air gap. The utility model cancels the resolver, and does not need to consider the air gap requirement of the resolver stator and rotor. The sweep bore condition does not occur, the motor structure reliability is ensured, and the product cost is further reduced.

[0011] 3、The traditional oil-cooled motor adopts a spline connection form, and the connection with the crankshaft needs to be connected through single-mass flywheel + torsional damper or double-mass flywheel and other parts. Then, the motor needs to be arranged with a space that can accommodate the flywheel + torsional damper, that is, the motor front shell. The three parts occupy too much axial space, so that the overall axial size of the motor is relatively long.

[0012] The utility model adopts a crankshaft direct connection form, avoids the failure mode of the traditional spline connection motor output shaft fracture, and improves the motor reliability. Because the crankshaft connection is directly fixed by using a screw with a thread fastening glue, the torque transmission effect is better. Because the flywheel disc, torsional damper, motor front shell and other structures are cancelled, the overall axial size of the motor is shorter, less material is used, the cost is low, and more vehicle cabins with strict axial size requirements can be adapted.

[0013] The utility model integrates the range extender motor shell with the engine assembly, adopts a rotor crankshaft direct connection scheme, further compresses the axial size of the range extender, and solves many technical problems.

[0014] 4. The motor cooling system of the utility model adopts oil channel oil shower cooling, and the cooling effect is superior to traditional annular oil injection cooling, double-pipe oil injection cooling and the like; meanwhile, the oil pipe arrangement and the opening requirement are low, the arrangement is simple, and excessive safety distance is not required, the motor axial dimension is further compressed, and the expandability of the scheme is improved.

[0015] 5. The utility model adopts the form that GCU is integrated with ECU, the integration degree of whole control unit is high after integration, parts are less, and control real-time performance is higher; hardware can satisfy information security related requirements; meanwhile, crankshaft signal + non-inductive control is adopted, the rotating transformer is removed, motor parts are reduced, and the cost is lower; the positive and negative rotation identification technology based on ECU crankshaft signal identification and bidirectional Hall sensor realizes engine crankshaft signal GCU working signal synchronization, and high and low speed rotating variable cancellation, non-inductive control technology scheme are realized.

[0016] 6. The utility model discloses a multi-in-one for engine cylinder block, oil pan, ECU, range extending motor control unit (GCU), range extending motor stator, range extending motor rotor high integration. Engine cylinder block and oil pan develop range extending motor stator shell, range extending motor stator is assembled with it, reduces motor stator shell mould development, casting, machining, assembly and the like process, improves assembly, makes assembly simple, realizes cost reduction, management and control. Engine oil pan and cylinder block design motor shell can realize liquid cooling flow passage design development, and form motor stator and rotor cooling cavity simultaneously, and this architecture is favorable to the design development of oil cooling or water cooling cooling circulation system. Meanwhile, the high integration of range extending motor control unit (GCU) and ECU effectively reduces the application quantity of electric control type product parts, axial dimension and the like, further reduces the cost, compresses the axial dimension of range extender, and improves the expandability of range extender scheme.

[0017] 7. The utility model discloses engine assembly cylinder block, oil pan design motor stator shell, improve motor stator assembly, reduce mould development quantity, reduce cost;

[0018] Engine assembly cylinder block, oil pan design motor stator shell, form independent cavity, provide the basis for oil cooling cooling system development. Oil cooling system can improve motor and electric control system performance, and high -efficient cooling can further reduce motor stator lamination thickness, reduce cost. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 It is the utility model explosion map;

[0020] Figure 2 It is the utility model whole axonometric drawing;

[0021] Wherein: 1, motor control unit; 2, control unit mainboard; 3, mechanical oil pump; 4, motor rear end cover; 5, cooling oil pipe; 6, motor stator; 7, motor rotor; 8, oil pan integrated motor lower shell; 9, cylinder integrated motor upper shell; 10, crankshaft. DETAILED DESCRIPTION

[0022] In order to better understand the purpose, structure and function of the utility model, the utility model is described in further detail below with reference to the drawings.

[0023] Figure 1 Exploded view, Figure 2 In the axonometric view, the motor control unit 1 is installed on the motor rear end cover 4 in cooperation and is fixed by a ring of standard screws, and the controller has IGBT, capacitor and other components inside, and meanwhile, the ECU function is integrated on the GCU internal mainboard in the patent, thereby forming the control unit mainboard 2, and the ECU, GCU and range extending motor three-in-one can be finally realized; meanwhile, the crankshaft signal + non-inductive control is adopted, the rotary transformer is removed, the motor components are reduced, the three-in-one + rotary transformer cancellation form makes the motor cost further reduced. The control unit mainboard 2 is installed between the motor control unit 1 and the motor rear end cover 4.

[0024] The control unit mainboard 2: the control system is designed to be integrated with the GCU and ECU, and is arranged at the axial rear end; the ECU is installed in the GCU, the ECU shell is cancelled, the ECU, GCU control board and driving board are combined into a PCB board, and the empty PCB position can be filled up. Meanwhile, the connector back surface is wired, the controller adopts the backpack type, the range extender assembly height is reduced, and the assembly assembly is facilitated.

[0025] The motor control unit 1 is arranged with a sol slot on the combined surface of the motor rear end cover 4, and is sealed by addition type silicone rubber. This sealing form is dry sealing, which not only ensures IP67 protection, but also is convenient for subsequent disassembly and maintenance;

[0026] The mechanical oil pump 3 is assembled in the motor rear end cover 4 and is fixed by a plurality of standard screws, and meanwhile, the mechanical oil pump 3 is connected with the oil inlet of the motor rotor 7 and the cooling oil pipe 5. When the motor rotor 7 operates, the mechanical oil pump 3 synchronously operates, and the cooling oil in the oil collecting groove arranged in the motor is transported to the oil cooler through the oil circuit for cooling. After being cooled by the oil cooler, part of the cooling oil is sprayed on the motor stator 6 through the cooling oil pipe 5 (radial cooling) or the cooling oil pan (axial cooling) for cooling, and part of the cooling oil cools the motor rotor 7 through the built-in oil circuit of the motor rotor 7. The oil collecting groove arranged in the motor collects the oil dripping from the motor stator 6 and the oil thrown out by the motor rotor 7, and then the cooling oil is returned to the stator and rotor through the oil filter, the mechanical oil pump 3 and the oil cooler, thereby forming a cooling cycle.

[0027] The mechanical oil pump 3 sucks up oil, part of which enters the rotor oil passage to cool the motor rotor 7, and part of which enters the cooling oil pipe 5 to cool the motor stator 6.

[0028] The motor stator 6 is fixed in the motor housing, the motor rotor 7 is connected with the crankshaft 10 in the motor housing, and the cooling oil pipe 5 is arranged in the motor housing and connected with the built-in oil passage of the motor rotor 7 and can spray the motor stator 6.

[0029] The motor rotor 7 is composed of a rotor support, silicon steel sheets, rotor end plates, etc. The silicon steel sheets are positioned and assembled on the rotor support in pieces through key grooves, and then fixed by the two rotor end plates;

[0030] The motor stator 6 is composed of a stator core, a stator winding mold, an enameled wire, and silicon steel sheets. The entire motor stator 6 is fixed in the motor housing through a plurality of mounting screws, and the motor stator 6 is provided with a positioning pin hole for auxiliary installation and positioning, so that the motor stator 6 will not be sucked together with the motor rotor 7 to produce bumps during installation;

[0031] The motor stator 6 and the motor rotor 7 are important components of the motor and directly participate in power generation of the motor. The motor stator 6 is designed and developed according to the performance of the range extender assembly, usually adopts a Hairpin winding form to realize high efficiency and miniaturization. The motor stator 6 is fixed in the motor housing integrated with the engine and the oil pan through a plurality of standard specification mounting screws without the need for thermal embedding, and the motor housing has no risk of thermal deformation. The motor rotor 7 is fixed on the crankshaft 10 through a plurality of mounting screws with threaded fastening glue and moves together with the crankshaft 10. The stator and rotor cores are aligned with a single-sided air gap;

[0032] The oil pan integrated motor lower housing 8 and the cylinder block integrated motor upper housing 9 are installed through a standard screw, and are coated with sealing glue to ensure IP67 sealing. After installation, a complete motor housing is formed. The motor housing is machined together with the cylinder block and the oil pan, and has higher strength than traditional motors. At the same time, this form of assembly will not produce a step difference at the motor housing, and the motor itself will not be radially offset, and the stator-rotor air gap can be guaranteed;

[0033] A bidirectional oil seal is arranged at the engine oil seal inside the engine cavity of the cylinder block integrated motor upper housing 9. Because the engine and the motor use different types of cooling lubricating oil, and each has a cooling circulation system, the types of cooling oil and the required oil temperature are different, so they are sealed separately to meet the performance. By using a bidirectional oil seal, the two cavities are isolated and distinguished, the IP67 sealing of the entire machine is guaranteed, and the product performance is good;

[0034] The whole machine assembly sequence: after the oil pan integrated motor lower shell 8, the cylinder body integrated motor upper shell 9 and the crankshaft 10 are assembled, the motor shell is formed; the motor rotor 7 is assembled through a plurality of rotor special mounting screws; the motor stator 6 is assembled through a positioning pin and a circle of mounting screws; the cooling oil pipe 5 is installed through a positioning support and a screw; the motor rear end cover 4 is installed on the rear end surface formed by the oil pan integrated motor lower shell 8 and the cylinder body integrated motor upper shell 9 through a plurality of standard screws; the mechanical oil pump 3 is embedded in the motor rear end cover 4 through a mounting screw, and is connected with the oil inlet of the motor rotor 7; finally, the motor control unit 1 is installed through a plurality of standard mounting screws and positioning pins.

[0035] Through the above design, the integrated oil-cooled direct-connected motor has the advantages of shorter total length, lighter weight (only the motor control part), lighter overall weight, shorter axial dimension and great saving of design and mold cost compared with the existing motor; the motor shell formed by the cylinder body, the oil pan and the machine together has higher strength and installation convenience than the traditional range extending motor.

[0036] It can be understood that the utility model is described through some embodiments, and those skilled in the art know that various changes or equivalent replacements can be made to these features and embodiments without departing from the spirit and scope of the utility model.In addition, under the guidance of the utility model, these features and embodiments can be modified to adapt to specific conditions and materials without departing from the spirit and scope of the utility model.Therefore, the utility model is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of the present application belong to the scope protected by the utility model.

Claims

1. A multi-functional, highly integrated crankshaft-driven range extender powertrain architecture, characterized in that: The device includes a motor control unit (1), a control unit main board (2), a mechanical oil pump (3), a motor rear end cover (4), a cooling oil pipe (5), a motor stator (6), a motor rotor (7), and a motor housing. The motor control unit (1) is mounted on the motor rear end cover (4), the control unit main board (2) is mounted between the motor control unit (1) and the motor rear end cover (4), the mechanical oil pump (3) is assembled inside the motor rear end cover (4), the mechanical oil pump (3) is connected to the oil inlet of the motor rotor (7) and the cooling oil pipe (5), the motor stator (6) is fixed inside the motor housing, the motor rotor (7) is connected to the crankshaft (10) inside the motor housing, and the cooling oil pipe (5) is located inside the motor housing and can spray the motor stator (6).

2. The multi-integrated crankshaft direct-drive range extender powertrain architecture according to claim 1, characterized in that: The control unit motherboard (2) integrates the ECU on the internal motherboard of the GCU, realizing the integration of ECU, GCU and range extender motor into one.

3. The multi-integrated crankshaft direct-drive range extender powertrain architecture according to claim 1, characterized in that: The motor control unit (1) and the rear end cover (4) of the motor are connected by a sol-gel tank, and the two are sealed by addition-curing silicone rubber.

4. The multi-integrated crankshaft direct-drive range extender powertrain architecture according to claim 1, characterized in that: The motor housing includes an oil pan integrated motor lower housing (8) and a cylinder block integrated motor upper housing (9); the oil pan integrated motor lower housing (8) and the cylinder block integrated motor upper housing (9) are connected and sealed with sealant.

5. The multi-integrated crankshaft direct-drive range extender powertrain architecture according to claim 4, characterized in that: The oil pan integrated motor lower housing (8) is an integration of the oil pan and the motor lower housing; the cylinder block integrated motor upper housing (9) is an integration of the engine cylinder block and the motor upper housing.

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