A connection structure of an outer rotor motor and a range extender highly integrated with an engine

Abstract

A kind of outer rotor motor and engine highly integrated range extender connection structure, belong to the technical field of range extender assembly for new energy vehicles, it is characterized in that: including engine integrated motor casing and the motor rotor connected on the crankshaft of the front of the engine integrated motor casing, the bracket on the front of the front of the engine integrated motor casing is connected with electronic control casing, electronic control casing rear is connected with rotary transformer, electronic control casing rear is inserted with motor stator, the inside of the front of the electronic control casing is inserted with motor cooling cavity inner shell, the periphery of the front of the electronic control casing is connected with electronic control back cover plate, electronic control back cover plate with between the electronic control casing is equipped with electronic control module connected on electronic control casing, range extender motor is outer rotor motor, compact structure, further shorten the axial dimension, outer rotor and air contact area is larger, heat dissipation condition is more optimal, while also more suitable for the water-cooling cooling of motor whole, can reach higher energy conversion efficiency.

Description

Technical Field

[0001] This utility model belongs to the technical field of range extender assembly for new energy vehicles, specifically relating to a range extender connection structure that highly integrates an external rotor motor and an engine. Background Technology

[0002] Traditional non-direct-drive range extender assemblies connect the engine and range extender motor via gears, flywheels, or torsional dampers, resulting in a complex system structure, increased failure probability, and larger axial dimensions, occupying more space and negatively impacting engine bay layout. While traditional direct-drive range extender assemblies simplify the structure, their integration is often low. The engine and range extender motor systems are manufactured separately, and the range extender motor stator and rotor assemblies are then assembled with the engine. Furthermore, the engine block and oil pan connection housing needs to be bolted to the motor housing and sealed with adhesive, requiring high assembly precision and complex processes. In addition, most traditional range extenders use internal rotor range extender motors, which have large axial dimensions, limited heat dissipation efficiency, lower output power, and a slightly more complex structure. Utility Model Content

[0003] The purpose of this utility model is to address the shortcomings of existing technologies by proposing a highly integrated range extender connection structure that integrates an external rotor motor with the engine. The motor rotor is directly connected to the engine crankshaft, eliminating components such as the flywheel, reducing axial dimensions, and occupying less space, which is highly beneficial for the overall vehicle layout. This structure integrates the range extender motor housing with the engine block and oil pan in a single unit, increasing integration, simplifying the range extender structure, and reducing the failure rate of the range extender system. The range extender motor is an external rotor motor with a compact structure, further shortening the axial dimension. The external rotor has a larger contact area with air, resulting in better heat dissipation and better compatibility with overall motor water cooling, achieving higher energy conversion efficiency. The technical solution is as follows:

[0004] A range extender connection structure highly integrated with an external rotor motor and an engine is characterized by: including an engine integrated motor housing 1 and a motor rotor 2 connected to a crankshaft on the front surface of the engine integrated motor housing 1; an electronic control housing 5 is connected to the front surface of a bracket on the front of the engine integrated motor housing 1; a rotary transformer 4 is connected to the rear surface of the electronic control housing 5; a motor stator 3 is inserted into the rear surface of the electronic control housing 5; a motor cooling chamber inner shell 6 is inserted into the center of the inner circle of the front surface of the electronic control housing 5; an electronic control rear cover plate 8 is connected to the periphery of the front surface of the electronic control housing 5; an electronic control module 7 connected to the electronic control housing 5 is provided between the electronic control rear cover plate 8 and the electronic control housing 5; and a cavity is formed between the electronic control housing 5 and the motor cooling chamber inner shell 6.

[0005] The overall assembly sequence of the range extender is as follows: after the engine is assembled, the motor rotor 2 is first fixed to the engine crankshaft with several screws. Then, the flange surface of the motor stator and controller assembly, which consists of the motor stator 3, rotary transformer 4, electronic control housing 5, motor cooling chamber inner shell 6, and electronic control module 7, is coated with glue and then fixed to the motor housing with screws. Finally, the electronic control rear cover 8 is fixed to the outside of the electronic control housing 5 with screws and glue, thus completing the assembly of the entire range extender.

[0006] The rotary transformer 4, also known as the resolver, includes a resolver stator and a resolver rotor. The resolver stator is mounted on the electrical control housing 5, and the resolver rotor is mounted on the support of the rotor 2. Alternatively, other position sensors can be used to confirm the initial position of the motor and provide feedback on the rotor speed to achieve precise control of the motor. The outer shell of the motor's cooling chamber is integrated into the electrical control housing 5. The inner shell 6 of the cooling chamber is fixed with screws and an interference fit in the cavity formed by the electrical control housing and the outer shell of the cooling chamber. The motor stator 3 is heated to 150 degrees Celsius and hot-embedded into the frozen outer shell of the motor's cooling chamber. The electrical control module 7 consists of IGBTs, capacitors, sensors, a main control chip, and copper busbars, and is installed in the electrical control housing 5. The electrical control rear cover 8 is fixed to the outside of the electrical control housing 5 with several screws and adhesive.

[0007] The beneficial effects of this utility model are as follows: the range extender motor is an external rotor motor with a compact structure, which further shortens the axial dimension. The external rotor has a larger contact area with the air, resulting in better heat dissipation conditions. It is also more compatible with the overall water cooling of the motor, thus achieving higher energy conversion efficiency. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0009] Figure 2 This is a schematic diagram of the overall assembly structure of this utility model;

[0010] In the diagram: 1. Engine integrated motor housing; 2. Motor rotor; 3. Motor stator; 4. Rotary transformer; 5. Electrical control housing; 6. Inner shell of motor cooling chamber; 7. Electrical control module; 8. Electrical control rear cover. Detailed Implementation

[0011] Reference Figure 1 Figure 2The aforementioned range extender connection structure, which integrates an external rotor motor with an engine, is characterized by: including an engine-integrated motor housing 1 and a motor rotor 2 connected to a crankshaft on the front surface of the engine-integrated motor housing 1; an electronic control housing 5 connected to the front surface of a bracket on the front of the engine-integrated motor housing 1; a rotary transformer 4 connected to the rear surface of the electronic control housing 5; a motor stator 3 inserted into the rear surface of the electronic control housing 5; a motor cooling chamber inner shell 6 inserted into the center of the inner circle of the front surface of the electronic control housing 5; an electronic control rear cover plate 8 connected to the periphery of the front surface of the electronic control housing 5; an electronic control module 7 connected to the electronic control housing 5 and the electronic control rear cover plate 8; and a cavity formed between the electronic control housing 5 and the motor cooling chamber inner shell 6.

[0012] The overall assembly sequence of the range extender is as follows: After the engine is assembled, the motor rotor 2 is first fixed to the engine crankshaft with several screws. Then, the flange surface of the motor stator and controller assembly, which consists of the motor stator 3, rotary transformer 4, electronic control housing 5, motor cooling chamber inner shell 6, and electronic control module 7, is coated with glue and then fixed to the engine integrated motor housing 1 with screws. Finally, the electronic control rear cover plate 8 is fixed to the outside of the electronic control housing 5 with screws and glue, thus completing the assembly of the entire range extender.

[0013] The rotary transformer 4, also known as the resolver, includes a resolver stator and a resolver rotor. The resolver stator is mounted on the electrical control housing 5, and the resolver rotor is mounted on the support of the rotor 2. Alternatively, other position sensors can be used to confirm the initial position of the motor and provide feedback on the rotor speed to achieve precise control of the motor. The outer shell of the motor's cooling chamber is integrated into the electrical control housing 5. The inner shell 6 of the cooling chamber is fixed with screws and an interference fit in the cavity formed by the electrical control housing and the outer shell of the cooling chamber. The motor stator 3 is heated to 150 degrees Celsius and hot-embedded into the frozen outer shell of the motor's cooling chamber. The electrical control module 7 consists of IGBTs, capacitors, sensors, a main control chip, and copper busbars, and is installed in the electrical control housing 5. The electrical control rear cover 8 is fixed to the outside of the electrical control housing 5 with several screws and adhesive.

[0014] The motor uses water cooling. One side of the electrical control housing 5 has a coolant inlet and a high-voltage connector, while the other side has a coolant outlet and a low-voltage connector. The low-temperature coolant first flows through the motor to achieve better performance, then flows through the controller, and finally flows out from the outlet. The water cooling system can make the motor temperature distribution more uniform and prevent localized overheating.

[0015] Of course, the above description is not intended to limit the present utility model, and the present utility model is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present utility model should also fall within the protection scope of the present utility model.

Claims

1. A range extender connection structure that highly integrates an external rotor motor and an engine, characterized in that: The device includes an engine integrated motor housing (1) and a motor rotor (2) connected to a crankshaft on the front surface of the engine integrated motor housing (1). An electronic control housing (5) is connected to the front surface of the bracket on the front surface of the engine integrated motor housing (1). A rotary transformer (4) is connected to the rear surface of the electronic control housing (5). A motor stator (3) is inserted into the rear surface of the electronic control housing (5). A motor cooling chamber inner shell (6) is inserted into the center of the front surface of the electronic control housing (5). An electronic control rear cover plate (8) is connected to the four edges of the front surface of the electronic control housing (5). An electronic control module (7) connected to the electronic control housing (5) is provided between the electronic control rear cover plate (8) and the electronic control housing (5).

2. The range extender connection structure with high integration of external rotor motor and engine according to claim 1, characterized in that: The rotary transformer (4), also known as the resolver, includes a resolver stator and a resolver rotor. The resolver stator is mounted on the electrical control housing (5), and the resolver rotor is mounted on the support of the motor rotor (2).

3. The range extender connection structure with high integration of external rotor motor and engine as described in claim 1, characterized in that: The outer shell of the motor cooling chamber is integrated on the electrical control housing (5), and the inner shell (6) of the motor cooling chamber is fixed on the electrical control housing (5) by screws and interference fit, forming a cavity between the electrical control housing (5) and the inner shell (6) of the motor cooling chamber.

4. The range extender connection structure with high integration of external rotor motor and engine according to claim 1, characterized in that: The electronic control rear cover (8) is fixed to the outside of the electronic control housing (5) by several screws and adhesive.

5. The range extender connection structure with high integration of external rotor motor and engine according to claim 1, characterized in that: The electronic control module (7) includes IGBTs, capacitors, sensors, a main control chip, and copper busbars.

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