A portable modular range extender

Abstract

The utility model provides a portable modularization rotor range extender belongs to pure electric vehicle special power system. The soft connection subassembly of this range extender is intermittently connected on the range extender assembly, the generator of range extender assembly is directly connected with engine, the exhaust manifold is fixedly arranged at the air outlet end of engine, the air inlet pipe is fixedly connected on the air inlet of engine, the oil supply system is fixedly arranged outside engine, the oil supply system is connected with the oil circuit of engine, the cooling system is fixedly arranged outside engine, the cooling system is connected with the cooling channel of engine, the power supply plug is arranged at the output end of generator, is used for the connection of generator and whole vehicle charging system and signal system, the engine adopts rotor engine. The range extender is flexible and adaptable in multiple scenes, and has the use scene of supplying power for whole vehicle and independent power generation, adopts compact lightweight design, is convenient for carrying storage and carrying, convenient to use, and the direct connection structure has low loss and high transmission efficiency.

Description

Technical Field

[0001] This utility model belongs to the technical field of dedicated power systems for pure electric vehicles, and in particular relates to a portable modular rotor range extender. Background Technology

[0002] With the rapid development of the new energy vehicle industry, pure electric vehicles are gradually becoming the mainstream in the market due to their advantages such as zero emissions and low noise. However, the driving range of pure electric vehicles is still limited by multiple factors, including battery capacity, ambient temperature, and the availability of charging infrastructure. Especially for medium- and long-distance travel or in low-temperature environments, the effective battery capacity decreases significantly, and range anxiety remains a prominent issue.

[0003] To extend the driving range of pure electric vehicles, range-extended electric drive systems are employed. Traditional range extenders typically use inline or V-type piston engines as power sources, generating electricity through a crankshaft-driven generator to replenish the battery. While such systems effectively alleviate the problem of insufficient driving range, they generally suffer from drawbacks such as large size, high weight, strong vibration, and complex installation. On the one hand, traditional piston-type range extenders usually occupy a significant amount of space in the engine compartment or trunk, making direct integration into pure electric vehicles without designated installation locations. On the other hand, the overall weight is typically between 150-200 kg, significantly increasing the vehicle's curb weight and reducing energy efficiency and driving experience.

[0004] In addition, traditional range extenders are mostly fixed structures, requiring vehicle body modifications for installation and maintenance. They are not easy to disassemble and reassemble, and are difficult to be used interchangeably across different vehicle models.

[0005] Currently, the market lacks a portable range extender that is small, lightweight, easy to install and disassemble, and can accommodate both the existing space layout of pure electric vehicles and the energy replenishment needs of various scenarios. Due to its compact structure, high power-to-weight ratio, and stable operation, the rotary engine provides a new technological path for realizing miniaturized and modular range extender systems. Utility Model Content

[0006] To address the problems existing in the background art, this utility model provides a portable modular rotor range extender, which is compact in size, lightweight, and flexible in assembly and disassembly.

[0007] The technical solution adopted by this utility model to solve its technical problem is: a portable modular rotor range extender, including a range extender assembly and a soft connection component. The soft connection component is intermittently connected to the range extender assembly. The range extender assembly includes a generator, an engine, an exhaust manifold, an intake pipe, a fuel supply system, a cooling system, and a power plug. The generator is coaxially and fixedly connected to the engine output shaft. The exhaust manifold is fixedly installed at the engine outlet. The intake pipe is fixedly connected to the engine intake. The fuel supply system is fixedly installed outside the engine and connected to the engine's fuel circuit. The cooling system is fixedly installed outside the engine and connected to the engine's cooling channel. The power plug is located at the generator output end and is used to connect the generator to the vehicle's charging system and signal system. The engine is a rotor engine.

[0008] The power plug includes a telescopic pin and a pin control button. The telescopic pin is telescopically installed on the output end of the generator. One end of the pin control button is fixedly connected to the telescopic pin, and the other end of the pin control button extends to the outside of the generator.

[0009] The flexible connection assembly includes a power plug, a high-voltage line, and an electric vehicle charging connector. The power plug and the electric vehicle charging connector are respectively connected to both ends of the high-voltage line. The power plug is used to match and connect with the power supply plug, and the electric vehicle charging connector is used to connect with the vehicle.

[0010] The soft connection assembly also includes a range extender control unit, which is connected to the electric vehicle charging port via a connector.

[0011] The portable modular rotor range extender also includes a mounting device, through which the range extender assembly is detachably and securely connected to the vehicle.

[0012] The range extender assembly is located at the rear of the vehicle, and the intake and exhaust manifold openings of the range extender assembly are located on the side of the vehicle.

[0013] The beneficial effects of this utility model are: the range extender is flexibly adaptable to multiple scenarios, solving the problems of pure electric power replenishment anxiety and resource idleness.

[0014] Designed for both electric vehicle charging and outdoor use, this range extender features a detachable and portable structure. It serves as a temporary charging station for long-distance electric vehicle travel, alleviating range anxiety caused by insufficient charging infrastructure. It can also be disassembled and stored for daily electric commutes, avoiding the long-term idleness and energy redundancy of traditional range extenders. Furthermore, its adaptability to outdoor power usage scenarios (such as camping and emergencies) further expands its value and improves resource utilization.

[0015] Optimizing power transmission and structural design improves the range extender's operating efficiency and installation adaptability. On one hand, the engine and generator are directly connected, reducing intermediate transmission losses. Combined with a lightweight and compact 30kW rotary engine, this reduces the overall weight and size while improving power transmission efficiency. On the other hand, the mounting system and coordinated control logic ensure that the range extender is stable, reliable, and operates efficiently when installed in a vehicle. It is suitable for limited spaces such as the trunk of pure electric vehicles and can automatically adjust start-stop based on battery charge, further optimizing energy consumption.

[0016] Improved portability and ease of use of the range extender, reducing user operation and maintenance costs. The detachable structure and lightweight design allow for quick assembly and disassembly as needed, enabling single-person operation and making transportation and storage more convenient; integrated key components and a dedicated charging module controller simplify system connections, and collaborative control logic enables intelligent linkage between the range extender and the vehicle, reducing manual intervention and operational complexity. Attached Figure Description

[0017] In the attached diagram:

[0018] Figure 1 This is a schematic diagram of the overall structure of the range extender of this utility model;

[0019] Figure 2 This is a schematic diagram showing the extended effect of the power plug structure of this utility model;

[0020] Figure 3 This is a schematic diagram of the retracted effect of the power plug structure of this utility model.

[0021] Figure 4 This is a schematic diagram illustrating the connection effect of the flexible connection component of this utility model;

[0022] Figure 5 This is a schematic diagram of the control unit structure of this utility model;

[0023] Figure 6 This is a schematic diagram of the fixing device structure of this utility model;

[0024] Figure 7 This is a schematic diagram of the internal structure of the rotor assembly of this utility model;

[0025] Figure 8 This is a simplified diagram illustrating the working principle of the range extender of this utility model;

[0026] Figure 9 This is a rendering of the overall vehicle layout of the range extender of this utility model;

[0027] Figure 10 This is a simplified diagram of the switching logic of the range extender of this utility model;

[0028] In the diagram: 1. Generator; 2. Engine; 3. Exhaust manifold; 4. Intake pipe; 5. Fuel supply system; 6. Cooling system; 7. Power plug; 8. Telescopic pin; 9. Pin control button; 12. Power plug; 13. High-voltage line; 14. Electric vehicle charging connector; 15. Range extender control unit; 16. Connector; 17. Limiting telescopic claw; 18. Flexible positioning cavity; 19. Rotor housing; 20. Side seal; 21. Center gear ring; 22. Corner seal; 23. Top seal. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings. The drawings are simplified schematic diagrams, illustrating only the basic structure of the present invention, and therefore only show the components relevant to the present invention.

[0030] A portable modular rotor range extender includes a range extender assembly and a flexible connection component, the flexible connection component being intermittently connected to the range extender assembly. The range extender assembly includes a generator 1, an engine 2, an exhaust manifold 3, an intake pipe 4, a fuel supply system 5, a cooling system 6, and a power supply plug 7.

[0031] The generator 1 is coaxially and fixedly connected to the output shaft of the engine 2 via a rigid coupling to achieve direct power transmission; the exhaust manifold 3 is fixedly installed at the outlet end of the engine 2 to guide the exhaust gas; the intake pipe 4 is fixedly connected to the intake port of the engine 2 to supply air; the fuel supply system 5 is fixedly installed outside the engine 2 and is connected to the fuel line of the engine 2; the cooling system 6 is fixedly installed outside the engine 2 and is connected to the cooling channel of the engine 2; the power plug 7 is installed at the output end of the generator 1 for connecting the generator 1 to the vehicle charging system and signal system to achieve power transmission and control signal interaction; the control unit is connected to both the fuel supply system 5 and the engine 2, and controls the fuel supply of the fuel supply system 5 and the ignition of the engine 2. The engine 2 is a rotary engine.

[0032] The control unit of the range extender consists of a processing module with a microcontroller as its core, which integrates a signal acquisition module, a drive execution module, a communication interaction module, and a power management module that supplies power to each component.

[0033] The control relationship of the control unit is as follows: First, the signal acquisition module collects the connection status signals between the range extender and the vehicle in real time and transmits these signals to the processing module. The processing module processes the acquired signals based on the preset mode switching logic. If it determines that the range extender is not connected, it outputs a command to maintain the pure electric mode. If it determines that the range extender is connected, it further receives the command signal for manually switching the mode. If no manual command is received, it drives the execution logic corresponding to the pure electric priority mode and controls the start and stop of the range extender according to the SOC threshold. When a manual command is received, it matches the corresponding trigger parameters (SOC or vehicle speed) according to the pure electric priority / range extender / high-speed sub-mode selected by the user, and outputs start / stop commands to the range extender through the drive execution module. At the same time, the communication interaction module establishes interaction with the vehicle system and feeds back the operating status of the range extender and the power generation parameters to the vehicle system, realizing the coordinated control of the control unit and the vehicle system.

[0034] The fuel supply system 5 includes a fuel tank, a fuel line, and a fuel injector. The fuel line connects the engine 2 to the fuel tank. The fuel injector is located at the connection between the fuel line and the engine 2. The fuel injector sprays fuel into the engine 2, and the fuel sprayed into the engine 2 mixes with air to form fuel vapor.

[0035] The cooling system 6 includes a water tank, a circulating pump, a heat exchanger, and coolant piping. Coolant is stored in the water tank, and the coolant piping connects the water tank to the cooling passage of engine 2. The circulating pump and heat exchanger are both connected to the coolant piping, forming a closed-loop cooling path. The circulating pump pumps the coolant to circulate, and the heat generated by engine 2 is absorbed and carried away by the coolant to maintain the engine at a reasonable operating temperature. The coolant is cooled as it flows through the heat exchanger. The exhaust gases from combustion in engine 2 are discharged through exhaust manifold 3, avoiding thermal interference.

[0036] When the range extender assembly is working, air enters the intake manifold of engine 2 through intake pipe 4, and at the same time, fuel supply system 5 injects fuel into the intake manifold. The fuel and air mix to form a combustible mixture, which enters the combustion chamber of engine 2. After compression and ignition, the mixture is burned, and the resulting thrust drives the rotor to rotate. Through a rigid coupling, the generator 1 is driven to operate synchronously, converting mechanical energy into electrical energy.

[0037] The power supply plug 7 includes a telescopic pin 8 and a pin control button 9. The telescopic pin 8 is telescopically mounted on the output end of the generator 1. One end of the pin control button 9 is fixedly connected to the telescopic pin 8, and the other end of the pin control button 9 extends to the outside of the generator 1. By operating the pin control button 9, the telescopic pin 8 can be extended and retracted. The power supply plug 7 integrates a signal harness that matches the pre-reserved interface of the vehicle. When the power supply plug 7 is plugged into the vehicle, a signal connection is established.

[0038] When the range extender is in use, operate the pin control button 9 to extend the telescopic pin 8 and establish a stable connection with the vehicle's charging and signaling systems. This triggers the range extender's start-up process. After startup, the electrical energy generated by the generator 1 is transmitted to the vehicle's charging system via the telescopic pin 8 to charge the vehicle's battery pack. Simultaneously, the telescopic pin 8 also transmits control signals between the range extender and the vehicle, enabling coordinated control between the two. When the range extender stops working, similarly, operate the pin control button 9 to disconnect the telescopic pin 8 from the vehicle.

[0039] The flexible connection assembly includes a power plug 12, a high-voltage line 13, and an electric vehicle charging connector 14. The power plug 12 and the electric vehicle charging connector 14 are respectively connected to the two ends of the high-voltage line 13. The power plug 12 is used to match and connect with the power supply plug 7, and the electric vehicle charging connector 14 is used to connect with the vehicle. When the power supply plug 7 is not directly applicable to the connection with the vehicle, the flexible connection assembly is activated, the power plug 12 is plugged into the power supply plug 7, and the electric vehicle charging connector 14 is plugged into the vehicle. The power plug 12 and the power supply plug 7 are male and female connectors of the same model.

[0040] The soft connection assembly also includes a range extender control unit 15. The range extender control unit 15 is connected to the electric vehicle charging connector 14 via a connector 16. Since the high-voltage line 13 does not have data transmission capabilities, when the range extender is connected to the vehicle using the soft connection assembly, it cannot establish a connection with the vehicle's signal system. The range extender control unit 15, which is connected to the electric vehicle charging connector 14 via the connector 16, can control the on / off of the range extender's power supply to the vehicle.

[0041] The portable modular rotor range extender also includes a fixing device. The range extender assembly is detachably and fixedly connected to the vehicle through the fixing device. The fixing device includes a fixing shell and multiple limiting telescopic claws 17. A flexible positioning cavity 18 is provided in the fixing shell. One side of the flexible positioning cavity 18 is open. The multiple limiting telescopic claws 17 are all installed at the edge of the open side of the flexible positioning cavity 18. The multiple limiting telescopic claws 17 are respectively located on each cavity wall of the flexible positioning cavity 18. The range extender assembly is placed in the flexible positioning cavity 18.

[0042] Multiple through windows are provided on the walls of the flexible positioning recess 18 of the fixed housing. The pipes and wiring harnesses of the range extender assembly pass through these through windows to connect with external components. A connector matching the mounting device is provided in the trunk of the vehicle. This connector securely fixes the mounting device in the trunk, ensuring that the range extender assembly and the vehicle body remain in a fixed position and do not sway during vehicle movement. The flexible material filling the flexible positioning recess 18 is a thermally conductive silicone sheet, which effectively conducts the heat generated by the range extender assembly during operation to the vehicle body for heat dissipation through the mounting device, thus combining flexible cushioning, positioning support, and heat dissipation performance.

[0043] The engine 2 includes a rotor housing 19, a side seal 20, a central gear ring 21, an angle seal 22, and a top seal 23. The rotor body is interactively installed in the rotor housing 19, and the rotor housing 19 seals and covers the rotor body. The central gear ring 21 on the rotor body is meshed with the engine output shaft. The side seal 20 is provided on the end face of the rotor body, and the angle seal 22 and the top seal 23 are provided at the corners of the rotor body.

[0044] The range extender assembly is located at the rear of the vehicle, and the intake pipe 4 and exhaust manifold 3 of the range extender assembly are located on the side of the vehicle.

[0045] The intake and exhaust of the range extender assembly are far from the occupants' breathing area, reducing the backflow of exhaust gas into the vehicle. The heat source is concentrated in the rear corner, away from the middle of the power battery and the core area of ​​the passenger compartment, which facilitates the addition of fireproof partitions and heat insulation layers between the range extender and the vehicle interior, improving the overall vehicle thermal safety. The range extender assembly is located at the rear of the vehicle, as far away from the driver's cabin as possible, and the main noise radiates to the rear, minimizing the impact on NVH.

[0046] The mode switching logic between the range extender and the vehicle system is triggered by detecting the connection status between the range extender and the vehicle. The specific execution flow is as follows:

[0047] The system first determines the connection status between the range extender and the vehicle. If the result is that the range extender is not connected, the vehicle will operate directly in pure electric mode. If the result is that the range extender is successfully connected, the system will proceed to the manual mode selection and judgment stage.

[0048] If the manual switching mode is not selected, the system will default to the pure electric priority mode. In this mode, the corresponding operation is executed based on the remaining power battery charge (SOC): when the power battery SOC is ≥20%, the vehicle maintains pure electric driving status; when the power battery SOC is <20%, the range extender starts and supplies power to the vehicle.

[0049] If the manual switching mode is selected, the system will enter the stage of automatically selecting pure electric / range-extended mode, which can be further switched to three operating sub-modes: pure electric priority, range-extended mode, and high-speed mode. Each sub-mode executes actions according to the corresponding parameter conditions: When switching to pure electric priority mode, the power battery SOC is used as the trigger. When SOC is ≥ 20%, pure electric driving is maintained, and when SOC is < 20%, the range extender is activated; when switching to range-extended mode, the power battery SOC is also used as the trigger. When SOC is ≥ 70%, pure electric driving is maintained, and when SOC is < 70%, the range extender is activated; when switching to high-speed mode, the vehicle speed is used as the trigger. When the vehicle speed is ≤ 90 km / h, pure electric driving is maintained, and when the vehicle speed is > 90 km / h, the range extender is activated.

[0050] When the range extension demand ends (e.g., when the battery is fully charged or the user manually shuts it off), the control unit controls the engine 2 to stop ignition and the fuel supply system 5 to stop fuel supply. The engine 2 then stops, and the generator 1 stops. The control button 9 is operated to operate the telescopic pin 8 to disconnect from the vehicle, or the soft connection assembly is operated to disconnect from the vehicle, i.e., the electrical connection is quickly disconnected.

[0051] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A portable modular rotor range extender, characterized in that: The system includes a range extender assembly and a flexible connection component. The flexible connection component is intermittently connected to the range extender assembly. The range extender assembly includes a generator (1), an engine (2), an exhaust manifold (3), an intake pipe (4), a fuel supply system (5), a cooling system (6), a power supply plug (7), and a control unit. The generator (1) is coaxially and fixedly connected to the output shaft of the engine (2). The exhaust manifold (3) is fixedly installed at the outlet of the engine (2). The intake pipe (4) is fixedly connected to the intake port of the engine (2). The fuel supply system (5) is fixedly installed at the outlet of the engine (2). (2) Externally, the oil supply system (5) is connected to the oil circuit of the engine (2), the cooling system (6) is fixedly installed outside the engine (2), the cooling system (6) is connected to the cooling channel of the engine (2), the power supply plug (7) is installed at the output end of the generator (1) for connecting the generator (1) to the vehicle charging system and signal system, the control unit is connected to both the oil supply system (5) and the engine (2), the control unit controls the oil supply of the oil supply system (5) and the ignition of the engine (2), the engine (2) is a rotary engine.

2. The portable modular rotor range extender according to claim 1, characterized in that: The power plug (7) includes a telescopic pin (8) and a pin control button (9). The telescopic pin (8) is telescopically installed on the output end of the generator (1). One end of the pin control button (9) is fixedly connected to the telescopic pin (8), and the other end of the pin control button (9) extends out to the outside of the generator (1).

3. A portable modular rotor range extender according to claim 2, characterized in that: The flexible connection assembly includes a power plug (12), a high-voltage line (13), and an electric vehicle charging connector (14). The power plug (12) and the electric vehicle charging connector (14) are respectively connected to the two ends of the high-voltage line (13). The power plug (12) is used to match and connect with the power supply plug (7), and the electric vehicle charging connector (14) is used to connect with the whole vehicle.

4. A portable modular rotor range extender according to claim 3, characterized in that: The soft connection assembly also includes a range extender control unit (15), which is connected to the electric vehicle charging connector (14) via a connector (16).

5. A portable modular rotor range extender according to claim 4, characterized in that: The portable modular rotor range extender also includes a fixing device. The range extender assembly is detachably and fixedly connected to the vehicle through the fixing device. The fixing device includes a fixing shell and multiple limiting telescopic claws (17). A flexible positioning cavity (18) is provided in the fixing shell. One side of the flexible positioning cavity (18) is open. Multiple limiting telescopic claws (17) are installed at the edge of the open side of the flexible positioning cavity (18). The multiple limiting telescopic claws (17) are respectively located on each cavity wall of the flexible positioning cavity (18). The range extender assembly is placed in the flexible positioning cavity (18).

6. A portable modular rotor range extender according to claim 5, characterized in that: The range extender assembly is located at the rear of the vehicle, and the inlets of the intake pipe (4) and exhaust manifold (3) of the range extender assembly are located on the side of the vehicle.

7. A portable modular rotor range extender according to claim 6, characterized in that: The fuel supply system (5) includes a fuel tank, a fuel line and an injector. The fuel line connects the engine (2) and the fuel tank. The injector is located at the connection between the fuel line and the engine (2). The injector injects fuel into the engine (2).

8. A portable modular rotor range extender according to claim 7, characterized in that: The cooling system (6) includes a water tank, a circulating pump, a heat exchanger and a coolant pipeline. The coolant is stored in the water tank. The coolant pipeline connects the water tank and the cooling channel of the engine (2). The circulating pump and the heat exchanger are both connected in the coolant pipeline. The coolant pipeline and the cooling channel are connected to form a closed-loop cooling path.

9. A portable modular rotor range extender according to claim 5, characterized in that: Multiple through windows are opened on the walls of the flexible positioning cavity (18) of the fixed shell, through which the pipes and wiring harnesses of the range extender assembly are connected to external components.

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