Range extender system hardware architecture
The range extender system hardware architecture, which uses a shared waterway and multi-stage sealing design, solves the problems of insufficient integration and modularity in existing technologies, and achieves a high-efficiency, compact and low-cost range extender system design, thereby improving the system's reliability and adaptability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-26
- Publication Date
- 2026-03-27
AI Technical Summary
Existing range extender systems are inadequate in terms of integration, modular design, cost, and assembly difficulty, and cannot meet the higher performance and production efficiency requirements of new energy vehicles.
It adopts a highly integrated hardware architecture, including a common waterway design and multi-segment sealing structure for the cylinder block, motor housing, oil pan, inner wall of motor water channel, motor stator, motor rotor, motor rear end plate, inverter brick module and controller rear housing. It achieves modular and compact design through connection methods such as bolt locking and hot-fitting combination.
It improves the modularity of the system, reduces manufacturing costs and assembly difficulty, enhances sealing performance and cooling efficiency, extends system life, and improves system reliability and adaptability.
Smart Images
Figure CN224054065U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model belongs to the technical field of range extender, specifically is a range extender system hardware architecture. BACKGROUND
[0002] The range extender electric vehicle integrates the driving smoothness of pure electric vehicle and the energy supplement convenience of traditional fuel vehicle, effectively solves the user pain point of current new energy vehicle in the endurance and charging aspect, and the traditional range extender usually realizes its function by assembling the range extender motor on the traditional engine, and the engine and motor are assembled as independent individuals, and this mode is mature in technology and high in feasibility.
[0003] However, with the continuous development of new energy vehicle technology, the market puts forward higher requirements on the performance of range extender system, in order to improve the overall efficiency of range extender, it is necessary to further improve the integration degree of range extender system hardware architecture, improve the power density of range extender assembly through optimization design and integration technology, at the same time, in order to realize more efficient production and assembly, the range extender system needs to develop towards the direction of modularization, reduce the assembly process through modular design, improve the flexibility and adaptability of assembly, to meet the needs of different vehicle models and configurations, in addition, reducing the manufacturing cost of range extender is one of the key factors to improve market competitiveness, therefore, it is particularly important to develop a range extender system hardware architecture with high integration, modularization and low cost. UTILITY MODEL CONTENT
[0004] In order to solve the problems in the background art, the utility model provides a range extender system hardware architecture.
[0005] In order to achieve the above-mentioned purpose, the utility model adopts the following technical scheme: a range extender system hardware architecture, comprising cylinder body and motor upper shell, oil pan and motor lower shell, motor water channel inner wall, motor stator, motor rotor, motor rear end plate, inverter brick module and controller rear shell body;
[0006] The motor outer shell and water channel outer wall comprise a cylinder body, a motor upper shell, an oil pan and a motor lower shell, the cylinder body, the motor upper shell, the oil pan and the motor lower shell are fixedly connected, a sealing band is arranged in the motor outer shell and the water channel outer wall, the motor water channel inner wall is hot-embeddedly connected with the motor stator and is fixed in the motor outer shell and the water channel outer wall, the motor rotor is installed on a crankshaft of the cylinder body and the motor upper shell and is used in cooperation with the motor stator, the motor rear end plate is sealingly and fixedly connected with the motor outer shell and the water channel outer wall and is sealingly arranged with the motor water channel inner wall, the inverter brick module is fixed on the motor rear end plate, the alternating current side of the inverter brick module is provided with three-phase output terminals, the three-phase high-voltage passages integrated on the motor rear end plate are connected with three-phase winding lead wires of the motor stator, the motor controller water inlet is arranged on the controller rear shell body, the motor controller water inlet is communicated with a water inlet of the inverter brick module, a water outlet of the inverter brick module is communicated with the controller rear shell body, a water outlet of the controller rear shell body is communicated with a water inlet of the motor outer shell and the water channel outer wall, thereby forming a motor and motor controller shared water channel, the motor and motor controller shared water channel is communicated with a motor water outlet, the motor water outlet is arranged on the cylinder body and the motor upper shell, and the motor controller low-voltage connector and the high-voltage interface are installed on the controller rear shell body.
[0007] The motor outer shell and water channel outer wall are formed by the upper half of the motor water channel outer wall of the cylinder body and the motor upper shell and the lower half of the motor water channel outer wall of the oil pan and the motor lower shell, and cooperate with the step sealing structure of the motor water channel inner wall to form cylinder side sealing.
[0008] The motor rear end plate and the motor outer shell and water channel outer wall are provided with a sol slot one, the motor water channel inner wall is provided with a sol slot two, the sol slot two and the sol slot one form an electric control side sealing through filling of high-temperature resistant sealing glue or sealing glue strips.
[0009] Cooling water of the motor and motor controller shared water channel flows into the motor controller water inlet, sequentially flows through the power module of the inverter brick module and the motor water channel outer wall, and finally is discharged through the motor water outlet.
[0010] Compared with the prior art, the utility model has the advantages of:
[0011] 1. High integration and modular design: the utility model integrates the cylinder body and the motor upper shell, the oil pan and the motor lower shell, the motor water channel inner wall, the motor stator, the motor rotor, the motor rear end plate, the inverter brick module and the controller rear shell body, thereby significantly reducing the types and quantities of parts and improving the modular degree of the system; the integrated design not only makes the structure of the range extender system more compact, but also greatly reduces the manufacturing cost and assembly difficulty and improves the production efficiency.
[0012] 2. Optimized assembly process: The utility model discloses through adopting bolt locking fixation, hot-embedding combination, keyway structure fixation and various connecting modes, the stability and reliability between various components are ensured, and the assembly efficiency is improved.
[0013] 3. Improved sealing performance: The utility model discloses multi-section type sealing design, through the circular sealing band between motor outer shell and water channel outer wall and motor water channel inner wall, motor rear end plate and motor water channel inner wall between electric control side sealing and many sealing structures, effectively solve the water jacket sealing problem of range extender system, this sealing design not only improves the sealing performance of system, also strengthens the waterproof and moisture-proof ability of system, prolongs the service life of system.
[0014] 4. Shared water channel design: The utility model discloses through design motor and motor controller shared water channel, has reduced the additional cooling pipeline between motor and electric control, has simplified the structure of cooling system, has reduced manufacturing cost, simultaneously, shared water channel design has improved the cooling efficiency, has guaranteed the stability and reliability of motor and inverter brick module in the working process.
[0015] 5. Flexible adaptation and cost reduction: The controller rear shell of the utility model integrates motor controller low-voltage connector, high-voltage interface and filter module and other key components, can change controller rear shell according to different needs without affecting overall structure, realizes the flexible adaptation of various interface needs of whole vehicle, this design not only improves the versatility and expandability of range extender system, also reduces manufacturing cost through reducing unnecessary parts and simplifying design.
[0016] In summary, the utility model discloses through the highly integrated hardware architecture, realizes the efficient, compact and low-cost design of range extender system, simultaneously, through multi-section type sealing and shared water channel design, improves the reliability and durability of system, reduces manufacturing cost and assembly difficulty, provides new solution for the development of new energy automobile field. BRIEF DESCRIPTION OF DRAWINGS
[0017] Figure 1 It is the front view of the utility model;
[0018] Figure 2 It is the right view of the utility model;
[0019] Figure 3 It is the rear view of the utility model;
[0020] Figure 4 It is the explosion view of the utility model;
[0021] Figure 5 It is the cylinder body side sealing and electric control side sealing schematic view of the utility model. DETAILED DESCRIPTION
[0022] The technical solutions in the utility model will be clearly and completely described below in combination with the drawings in the utility model embodiments. Obviously, the described embodiments are only a part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all the other embodiments obtained by those skilled in the art without creative labor fall within the scope of the utility model.
[0023] The embodiment discloses a range extender system hardware architecture, comprising a cylinder and an upper motor shell 1, an oil pan and a lower motor shell 2, a motor water channel inner wall 3, a motor stator 4, a motor rotor 5, a motor rear end plate 6, an inverter brick module 7 and a controller rear shell 8.
[0024] The cylinder and the upper motor shell 1 are fixedly connected with the oil pan and the lower motor shell 2, and a semi-annular sealing band in the inner cavity forms a circular sealing band after assembly, together constituting a motor outer shell and a water channel outer wall. The cylinder and the upper motor shell 1 and the oil pan and the lower motor shell 2 each have a semi-annular sol slot on the end face of the electric control side, and a complete circular sol slot one is formed on the electric control side after assembly. The motor water channel inner wall 3 is hot-embeddedly connected with the motor stator 4 and is fixed in the motor outer shell and the water channel outer wall through a key groove structure. The motor rotor 5 is installed on the crankshaft of the cylinder and the upper motor shell 1 through a stop opening positioning pin and is used in cooperation with the motor stator 4. The motor rear end plate 6 is fixedly connected with the motor outer shell and the water channel outer wall through bolts. The cooperation part of the motor rear end plate 6 with the sol slot one and the sol slot two is a plane structure. The inverter brick module 7 is fixed on the motor rear end plate 6. The alternating current side of the inverter brick module 7 is provided with three-phase output terminals, which are connected with three-phase winding leads of the motor stator 4 through a three-phase high-voltage passage integrated on the motor rear end plate 6. The controller rear shell 8 is provided with a motor controller water inlet 10. The motor controller water inlet 10 is communicated with a water inlet of the inverter brick module 7 through an internal water channel of the controller rear shell 8. A water outlet of the inverter brick module 7 is communicated with the controller rear shell. A water outlet of the controller rear shell 8 is connected with a motor water inlet, thereby forming a motor and motor controller shared water channel 11. The motor and motor controller shared water channel 11 is communicated with a motor water outlet 9. The motor water outlet 9 is arranged on the cylinder and the upper motor shell 1. The controller rear shell 8 is provided with a motor controller low-voltage connector 12 and a high-voltage interface 13.
[0025] The motor outer shell and the water channel outer wall are formed by assembling an upper half of the motor water channel outer wall of the cylinder and the upper motor shell 1 and a lower half of the motor water channel outer wall of the oil pan and the lower motor shell 2, and cooperate with a stepped sealing structure of the motor water channel inner wall 3, thereby forming a cylinder side sealing 14.
[0026] The high-temperature resistant sealant or sealant strip is filled in the sol slot one of the electric control side end of the outer wall of the motor water channel and the sol slot two of the electric control side end of the inner wall 3 of the motor water channel, and then the bolt is locked to fix the motor rear end plate 6 and the outer wall of the motor water channel, and the electric control side sealing 15 is formed.
[0027] The controller rear shell 8 is assembled on the motor rear end plate 6, the controller water channel and the internal water channel of the motor form a shared water channel, the cooling water flows into from the motor controller water inlet 10, passes through the water inlet channel in the controller rear shell, the inverter brick module 7, the water outlet channel of the controller rear shell and the internal water channel of the motor, and finally is discharged through the motor water outlet 9.
[0028] When the utility model is used, the direct current provided by the battery is converted into alternating current through the inverter brick module 7, the converted alternating current is transported to the motor stator 4, the motor stator 4 is composed of a series of coils, when the alternating current passes through these coils, a rotating magnetic field is generated, the motor rotor 5 is composed of a permanent magnet or a core with a conductor, when the rotating magnetic field generated by the motor stator 4 interacts with the motor rotor 5, electromagnetic induction force (Lorentz force) is generated in the rotor, the electromagnetic induction force drives the motor rotor 5 to start rotating, thereby realizing the transmission of mechanical energy, in the range extender system, the motor rotor 5 is directly connected with the crankshaft of the engine, so the rotation of the motor rotor 5 drives the crankshaft to rotate, the cooling water flows into from the motor controller water inlet 10, sequentially flows through the power module of the inverter brick module 7 and the motor water channel, the cooling water circulates in the outer wall of the motor water channel and carries away the heat generated by the inverter brick module 7 and the motor stator 4, finally, the cooling water is discharged through the motor water outlet 9, and the cooling is completed, the inverter brick module 7 is the core part of the motor controller, is responsible for the conversion and transmission of electric energy, the three-phase high-voltage passage integrated on the motor rear end plate 6 ensures that the electric energy is transmitted from the inverter brick module 7 to the motor stator 4 efficiently, the motor controller low-voltage connector 12 and the high-voltage interface 13 integrated on the controller rear shell 8 are used for electrical connection with the whole vehicle, realize the control and management of the range extender system, and the utility model realizes the efficient, compact and low-cost design of the range extender system through the highly integrated hardware architecture.
[0029] It is obvious for those skilled in the art that the utility model is not limited to the details of the above exemplary embodiments, and the utility model can be realized in other assembly forms without departing from the spirit or basic characteristics of the utility model. Therefore, no matter from which point, the embodiments should be regarded as exemplary and non-restrictive, the scope of the utility model is defined by the appended claims instead of the above description, and therefore all changes falling within the meaning and scope of the equivalent conditions of the claims should be included in the utility model. Any figure reference in the claims should not be regarded as limiting the involved claims.
Claims
1. A range extender system hardware architecture, characterized by: It comprises cylinder and motor upper shell (1), oil pan and motor lower shell (2), motor water channel inner wall (3), motor stator (4), motor rotor (5), motor rear end plate (6), inverter brick module (7) and controller rear shell (8). The motor outer shell and water channel outer wall comprise cylinder and motor upper shell (1) and oil pan and motor lower shell (2), which are fixedly connected, and are provided with a sealing band inside; the motor water channel inner wall (3) is hot-embeddedly connected with the motor stator (4) and fixed in the motor outer shell and water channel outer wall; the motor rotor (5) is installed on the crankshaft of the cylinder and motor upper shell (1) and cooperatively used with the motor stator (4); the motor rear end plate (6) is sealingly and fixedly connected with the motor outer shell and water channel outer wall and sealingly arranged with the motor water channel inner wall (3); the inverter brick module (7) is fixed on the motor rear end plate (6), and the alternating current side of the inverter brick module (7) is provided with three-phase output terminals, which are connected with the three-phase winding lead wires of the motor stator (4) through the three-phase high-voltage passages integrated on the motor rear end plate (6); the controller rear shell (8) is provided with a motor controller water inlet (10), which is in communication with the water inlet of the inverter brick module (7); the water outlet of the inverter brick module (7) is in communication with the controller rear shell (8); the water outlet of the controller rear shell (8) is in communication with the water inlet of the motor outer shell and water channel outer wall, thereby forming a motor and motor controller shared water channel (11), which is in communication with a motor water outlet (9) arranged on the cylinder and motor upper shell (1); the controller rear shell (8) is installed with a motor controller low-voltage connector (12) and a high-voltage interface (13).
2. The hardware architecture of a range extender system according to claim 1, wherein: The motor outer shell and water channel outer wall are formed by the upper half of the motor water channel outer wall of the cylinder and motor upper shell (1) and the lower half of the motor water channel outer wall of the oil pan and motor lower shell (2), and are cooperatively arranged with the stepped sealing structure of the motor water channel inner wall (3) to form a cylinder side sealing (14).
3. The hardware architecture of a range extender system according to claim 1, wherein: The motor rear end plate (6) and the motor outer shell and water channel outer wall are provided with a sol slot one, and the motor water channel inner wall (3) is provided with a sol slot two, which form an electric control side sealing (15) by filling high-temperature resistant sealing glue or sealing glue strips.
4. The hardware architecture of a range extender system according to claim 1, wherein: The cooling water of the motor and motor controller shared water channel (11) flows into the motor controller water inlet (10), sequentially flows through the power module of the inverter brick module (7) and the motor water channel outer wall, and is finally discharged through the motor water outlet (9).