Range extender system and extended-range vehicle

Abstract

The present application provides a range extender system and an extended-range vehicle. The range extender system comprises a generator, an engine, and a sealing end plate. In the distribution direction of the engine and the generator, one end of an output crankshaft of the engine extends out of a cylinder block by means of a mounting hole, and the other end thereof is connected to a rotor of the generator; the sealing end plate is provided with a passage allowing the output crankshaft to pass through; the sealing end plate is located between the engine and the generator; the sealing end plate is used for sealing a gap between the motor and the engine; and when splashing toward the engine, cooling oil in a cavity of the generator can be blocked by the sealing end plate, improving the sealing performance of a connection position between the engine and the generator, thereby reducing the risk of cooling oil leaking through the gap, improving the stability of the heat dissipation effect of the generator, and reducing the risk of functional degradation or even failure of the generator, the range extender system, and the extended-range vehicle caused by high generator temperature.

Description

A range extender system and a range-extended vehicle

[0001] This application claims priority to Chinese Patent Application No. 202422082321.2, filed with the State Intellectual Property Office of China on August 26, 2024, entitled “A Range Extender System and a Range Extender Vehicle”, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of new energy vehicle technology, and in particular to a range extender system and a range-extended vehicle. Background Technology

[0003] With the rapid development of new energy technologies, new energy vehicles are being used more and more widely. New energy vehicles consist of batteries and electric motors. Batteries are used to power electric motors, and electric motors are used to drive the vehicle. The driving range of a vehicle is an important criterion for evaluating new energy vehicles. As the requirements for vehicle driving range continue to increase, range-extended electric vehicles are gradually standing out.

[0004] The range extender system is a key component of range-extended electric vehicles (REEVs), consisting of an engine and a generator. The generator converts the mechanical energy from the engine's rotation into electrical energy, which is then stored in the battery to charge it. This results in a longer driving range for the vehicle, solving the range anxiety problem of pure electric vehicles. It also provides the driving experience of a pure electric vehicle, with no power jerking or interruption during driving, making REEVs a technology that more and more automakers are choosing.

[0005] In range extender systems, generator cooling methods include water cooling and oil cooling. In oil-cooled generators, cooling oil is present inside the generator. The cooling oil flows through heat-generating components such as the stator, windings, and rotor, carrying away their heat to achieve generator cooling. If the range extender system is a direct-drive system, meaning the engine's output crankshaft is directly connected to the rotor, the generator housing cover needs to be removed, opening the generator's internal cavity and exposing the stator and rotor to facilitate the connection between the output crankshaft and the rotor. In this case, the generator housing cannot form a sealed component, posing a risk of cooling oil leakage. Cooling oil leakage can lead to poorer generator cooling, increased temperature, or even generator failure.

[0006] Therefore, improving the sealing performance of direct-drive range extender systems is a technical problem that urgently needs to be solved.

[0007] Application content

[0008] This application provides a range extender system and a range-extended vehicle, which can improve the sealing performance of the range extender system.

[0009] The first aspect of this application provides a range extender system, including a generator, an engine, and a sealing end plate. The generator includes at least a housing, a stator, and a rotor. The stator and rotor are both mounted in the housing and located within a cavity enclosed by the housing. The engine includes at least a cylinder block and an output crankshaft. The cylinder block is connected to the housing. Along the distribution direction of the engine and the generator, one end of the output crankshaft extends out of the cylinder block through a mounting hole, and the other end is directly connected to the rotor. The sealing end plate is provided with a channel for the output crankshaft to pass through. Along the distribution direction of the engine and the generator, the sealing end plate is located between the engine and the generator, and the sealing end plate is used to seal the gap between the generator and the engine.

[0010] In this application, the sealing end plate is used to seal the gap between the generator and the engine. When the cooling oil in the generator cavity splashes towards the engine, it can be blocked by the sealing end plate, which improves the sealing performance of the connection between the engine and the generator, thereby reducing the risk of cooling oil leakage through the gap. This improves the stability of the generator's heat dissipation effect and reduces the risk of functional degradation or even failure of the generator, range extender system, and range-extended vehicle due to high generator temperature.

[0011] In one possible design, the sealing end plate includes a body and a connecting part. Along the radial direction of the sealing end plate, the connecting part is located outside the body and is clamped and fixed by the cylinder and the housing.

[0012] In this application, the connecting part is clamped and fixed by the cylinder block and the housing, which reduces the risk of the sealing end plate detaching from the engine and generator, thereby improving the connection stability between the sealing end plate and the engine and generator. This, in turn, helps to improve the sealing performance of the connection position between the engine and generator, and reduces the risk of cooling oil in the generator cavity leaking through the connection position between the engine and generator.

[0013] In one possible design, the cylinder block and the housing are fixedly connected by a first fastener, and a first through hole is provided at the connection for the first fastener to pass through.

[0014] In this application, a portion of the first fastener is located within the first through hole. The first fastener can limit the sealing end plate, thereby reducing the risk of displacement or even detachment from the generator and engine during the installation, transportation, and use of the range extender system. This further improves the connection stability between the sealing end plate and the engine and generator, which in turn helps to improve the sealing performance of the connection between the engine and the generator, thereby reducing the risk of cooling oil leakage.

[0015] In one possible design, the body includes a first body and a second body. The second body is located between the first body and the connecting part. One end of the second body is connected to the connecting part, and the other end of the second body is connected to the first body. The second body is inclined along the distribution direction of the engine and the generator, and the channel is located on the first body. In the distribution direction of the engine and the generator, the first body abuts against the cylinder block, and the first body and the cylinder block are fixedly connected by a second fastener.

[0016] In this application, the connecting portion of the sealing end plate is clamped by the engine block and the generator housing. Simultaneously, the first body abuts against the engine block. This reduces the risk that all the forces exerted on the sealing end plate by the engine and generator will be concentrated at the connecting portion, thereby reducing the risk of damage to the connecting portion during the operation of the range extender system and extending the service life of the sealing end plate. The fixed connection between the first body and the cylinder block further enhances the stability of the connection between the sealing end plate and the engine and generator, which in turn improves the sealing performance of the connection between the engine and generator, thus reducing the risk of coolant leakage.

[0017] In one possible design, the range extender system also includes a first seal located between the sealing end plate and the housing, and the first seal is located inside the cylinder block.

[0018] In this application, the first seal can reduce the risk of cooling oil inside the generator entering the engine through the gap between the housing and the sealing end plate and the first fastener, and also reduce the risk of cooling oil inside the generator overflowing to the outside through the gap between the housing and the sealing end plate, thereby improving the sealing performance of the connection between the engine and the generator and reducing the risk of cooling oil leakage.

[0019] In one possible design, the range extender system also includes a first oil seal located within the channel, radially along the sealing end plate, with one side of the first oil seal abutting against the sidewall of the channel and the other side of the first oil seal abutting against the output crankshaft.

[0020] In this application, the first oil seal can seal the gap between the output crankshaft and the sealing end plate, thereby reducing the risk of cooling oil in the generator entering the outside or the engine through the gap between the output crankshaft and the sealing end plate, thus improving the sealing performance of the connection between the engine and the generator.

[0021] In one possible design, the first body includes an oil seal mounting portion that extends toward the housing along the distribution direction of the engine and generator, and forms a channel. Along the radial direction of the sealing end plate, the first oil seal abuts against the oil seal mounting portion.

[0022] In this application, when the thickness of the sealing end plate is small, the oil seal mounting portion extending along the distribution direction of the engine and generator can increase the length of the channel, so that the length of the channel meets the installation size requirements of the first oil seal. This reduces the risk that the first oil seal may be difficult or even impossible to install due to the small length of the channel. In addition, provided that the length of the channel meets the installation size requirements of the first oil seal, the thickness at the edge of the sealing end plate can be reduced, which helps to reduce the overall weight of the sealing end plate and the range extender system.

[0023] In one possible design, the range extender system further includes a second oil seal, at least a portion of which is located within a mounting hole along the radial direction of the output crankshaft. One side of the second oil seal abuts against the cylinder block, and the other side of the second oil seal abuts against the output crankshaft. The cylinder block and the sealing end plate form a first cavity, and a second cavity exists between the first oil seal and the second oil seal. A first venting channel is provided on the sealing end plate, and the second cavity is connected to the first cavity through the first venting channel. A second venting channel is provided on the cylinder block, and the first cavity is connected to the outside through the second venting channel.

[0024] In this application, the first cavity is connected to the outside through the second venting channel, and the first cavity is connected to the second cavity through the first venting channel, so as to balance the pressure between the second cavity and the outside, and reduce the risk of the first oil seal and the second oil seal deforming under the action of pressure difference, resulting in sealing failure.

[0025] In one possible design, a first exhaust passage is located on the side of the sealing end plate facing the cylinder body; the cylinder body includes a body and a mounting part, the mounting part is located on the outer periphery of the body, the mounting part and the sealing end plate form a first cavity, the mounting part is connected to the housing, and a second vent passage is located in the mounting part and passes through the mounting part radially along the cylinder body.

[0026] In this application, the second venting channel is provided on the mounting part for connection with the housing. The housing can cover part of the second venting channel, thereby reducing the area of ​​the second venting channel exposed to the outside, and thus reducing the risk of external liquid entering the range extender system through the second venting channel.

[0027] In one possible design, the outline of the second ventilation channel is bent.

[0028] In this application, when there is liquid such as condensate or rainwater on the outside of the cylinder block, the sidewall of the second vent passage can block at least part of the liquid, thereby reducing the risk of external liquid entering the engine through the second vent passage, and also reducing the risk of external liquid entering the space between the cylinder block and the sealing end plate through the second vent passage and the first vent passage, thereby reducing the risk of external liquid entering the generator through the gap between the sealing end plate and the housing, thus improving the waterproof performance of the range extender system.

[0029] A second aspect of this application provides a range-extended vehicle, including a frame and a power system mounted on the frame. The power system includes at least a battery, an electric motor, and a range extender system as described above. The electric motor is connected to the battery and is used to drive the range-extended vehicle. A generator is connected to the battery and is used to supply power to the battery.

[0030] In this application, the generator and engine are separated by a sealing end plate, the gap between the generator housing and the sealing end plate is sealed by a first seal, and the shaft connection position of the range extender system is sealed by a first oil seal and a second oil seal. This improves the sealing performance of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leaking to the outside through the gap between the engine and the generator. This improves the stability of the generator's heat dissipation effect and reduces the risk of generator thermal runaway, thereby reducing the risk of functional degradation or even failure of the generator, range extender system, and range-extended vehicle. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 is a schematic diagram of the power system connection of a range-extended electric vehicle;

[0033] Figure 2 is a schematic diagram of the engine and generator in one embodiment of the range extender system before the improvement;

[0034] Figure 3 is a schematic diagram of the engine and generator in another embodiment of the range extender system before the improvement;

[0035] Figure 4 is an exploded view of the range extender system provided in this application;

[0036] Figure 5 is a structural cross-sectional view of the range extender system provided in this application in one embodiment;

[0037] Figure 6 is a structural cross-sectional view of the sealing end plate in Figure 4 in one embodiment;

[0038] Figure 7 is a magnified view of part I in Figure 5;

[0039] Figure 8 is a magnified view of part II in Figure 5;

[0040] Figure 9 is a structural cross-sectional view of the sealing end plate in Figure 4 in one embodiment;

[0041] Figure 10 is a schematic diagram of the sealing end plate in Figure 4 in one embodiment;

[0042] Figure 11 is a left view of Figure 10;

[0043] Figure 12 is a schematic diagram of the cylinder block of the engine in Figure 4 in one embodiment;

[0044] Figure 13 is a cross-sectional view of the cylinder block and sealing end plate at the first and second venting passages.

[0045] Figure 14 is a magnified view of a partial structure at the second ventilation channel in Figure 12.

[0046] Reference numerals: 01-Frame; 02-Wheel; 1-Engine; 11-Cylinder block; 111-Second ventilation passage; 112-Body; 113-Mounting part; 12-Output crankshaft; 13-Flywheel; 14-First cavity; 15-Mounting hole; 2-Generator; 21-Housing; 22-Stator; 23-Rotor; 24-Opening; 25-Gap; 3-Battery; 4-Motor; 5-Sealing end plate; 51-Body part; 511-First body; 511A-Channel; 511B-Oil seal mounting part; 512-Second body; 513-Second through hole; 52-Connecting part; 521-First through hole; 53-First ventilation passage; 6-First fastener; 7-Second fastener; 8-Third fastener; 9-First seal; 1A-First oil seal; 1B-Second oil seal; 1C-Second cavity. Detailed Implementation

[0047] To better understand the technical solution of this application, the embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0048] It should be understood that the described embodiments are merely some, not all, of the embodiments in this application. All other embodiments obtained by those skilled in the art based on the embodiments in this application without inventive effort are within the scope of protection of this application.

[0049] The terminology used in the embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The singular forms “a,” “the,” and “the” used in the embodiments of this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.

[0050] It should be understood that the term "and / or" used in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0051] With the rapid development of the new energy vehicle industry, range-extended electric vehicles have become the technology route chosen by more and more car companies due to their advantages such as solving the range anxiety problem of pure electric vehicles and providing a fully electric driving experience.

[0052] Figure 1 is a schematic diagram of the power system connection of a range-extended electric vehicle. As shown in Figure 1, the body of the range-extended electric vehicle includes at least a frame 01 and wheels 02 mounted on the frame 01. The number of wheels 02 can be one, two, or four. The power system of the range-extended electric vehicle is mounted on the frame 01. The power system includes at least an electric motor 4 connected to the wheels, a battery 3 connected to the electric motor 4, a generator 2 connected to the battery 3, and an electric motor 4 connected to the generator 2. The generator 2 and the engine 1 are combined to form the range extender system of the range-extended electric vehicle, which can charge the battery 3, thereby improving the range of the battery 3.

[0053] Figure 2 is a schematic diagram of the structure of engine 1 and generator 2 in one embodiment of the range extender system. As shown in Figure 2, engine 1 includes an output crankshaft 12, which can rotate around its own axis. Generator 2 includes a stator 22 and a rotor 23 disposed in a cavity enclosed by housing 21. The stator 22 is sleeved on the outside of rotor 23, and a resistance coil for connecting to battery 3 is wound on the stator 22. The output crankshaft 12 is connected to rotor 23 through flywheel 13. When the range extender system is working, the output crankshaft 12 of engine 1 can drive rotor 23 to rotate, causing the magnetic field generated by rotor 23 to change. According to the principle of magnetism generating electricity, an induced current is generated in the resistance coil on stator 22, that is, generator 2 can convert the mechanical energy generated by engine 1 into electrical energy and store it in battery 3, thereby realizing the charging of battery 3.

[0054] To ensure the normal and stable operation of the generator, it is necessary to cool it to reduce the risk of damage due to overheating. Typically, the generator is cooled by oil. A generator that uses oil cooling is simply called an oil-cooled motor. In an oil-cooled motor, there is cooling oil inside the generator. The cooling oil can flow through the heat-generating components inside the generator, such as the stator, rotor, and windings, and carry away their heat to achieve the cooling of the generator.

[0055] When the output crankshaft 12 and the rotor 23 are indirectly connected, as shown in Figure 2, a flywheel 13 is provided on the output crankshaft 12, and the rotor 23 and the flywheel 13 are connected by a spline. This connection structure results in a large overall size of the range extender system, which is not conducive to the development of the range extender system towards low cost, miniaturization and lightweight. In view of this, the range extender system can be set as a direct-drive range extender system, that is, the output crankshaft and the rotor are directly connected, so as to reduce the overall size of the range extender system.

[0056] The structure of the direct-drive range extender system is shown in Figure 3. The top cover of the generator 2 housing 21 is eliminated, allowing the engine cavity to be opened and forming an opening 24. The stator 22 and rotor 23 inside are exposed at the opening 24. The output crankshaft 12 extends into the housing 21 through the opening 24 and is directly connected to the rotor 23. The direct-drive range extender system has a smaller size. At this time, the generator 2 housing 21 cannot form a closed component. When the generator 2 is an oil-cooled motor, the risk of leakage of the cooling oil inside the generator 2 at the opening 24 and the gap 25 between the housing 21 and the engine cylinder block 11 is high. The leakage of cooling oil will cause the generator 2 to have a poor cooling effect, temperature rise, or even failure. Moreover, the leaked cooling oil also poses risks such as environmental pollution and fire, making the application of oil-cooled motors a safety hazard.

[0057] To address the sealing issue of the oil-cooled motor in a direct-drive range extender system, this application provides a range extender system with better sealing performance. Figure 4 is an exploded view of the range extender system provided in this application. As shown in Figure 4, the range extender system provided in this application includes a generator 2, an engine 1, and a sealing end plate 5, wherein the generator 2 is an oil-cooled motor. Figure 5 is a cross-sectional view of the range extender system. As shown in Figure 5, the sealing end plate 5 is located between the generator 2 and the engine 1 along the distribution direction X of the engine 1 and the generator 2. The generator 2 includes at least a housing 21, a stator 22 and a rotor 23. The stator 22 and the rotor 23 are both installed in the housing 21 and located in the cavity enclosed by the housing 21. The engine 1 includes at least a cylinder block 11 and an output crankshaft 12. Along the distribution direction X of the engine 1 and the generator 2, one end of the output crankshaft 12 extends to the outside of the cylinder block 11 through a mounting hole on the cylinder block 11, and the other end is connected to the rotor 23. The sealing end plate 5 is provided with a channel 511A for the output crankshaft 12 to pass through. That is, the output crankshaft 12 first passes through the channel 511A on the sealing end plate 5 and then connects to the rotor 23. The sealing end plate 5 is used to seal the gap between the generator 2 and the engine 1.

[0058] In this embodiment, the sealing end plate 5 is used to seal the gap between the generator 2 and the engine 1. When the cooling oil in the generator 2 cavity splashes towards the engine 1, it can be blocked by the sealing end plate 5, improving the sealing performance of the connection between the engine 1 and the generator 2. This reduces the risk of cooling oil leakage from the generator cavity through the gap between the cylinder block 11 and the housing 21, reducing the safety hazards caused by cooling oil leakage. It also improves the stability of the generator's heat dissipation effect, thereby reducing the risk of functional degradation or even failure of the generator, range extender system, and range-extended vehicle due to high generator temperature.

[0059] The sealing end plate can be made of stamped steel plate, die-cast aluminum, injection molded non-metallic materials, etc. The embodiments of this application do not impose special limitations on the material type of the sealing end plate.

[0060] Figure 6 is a cross-sectional view of the sealing end plate 5 in one embodiment. As shown in Figure 6, the sealing end plate 5 includes a body portion 51 and a connecting portion 52. Along the radial direction of the sealing end plate 5, the connecting portion 52 is located outside the body portion 51. Referring to Figures 5 and 6, the connecting portion 52 is clamped and fixed by the cylinder block 11 of the engine 1 and the housing 21 of the generator 2 to reduce the risk of the sealing end plate 5 detaching from the engine 1 and the generator 2, thereby improving the connection stability between the sealing end plate 5 and the engine 1 and the generator 2. This, in turn, helps to improve the sealing performance of the connection position between the engine 1 and the generator 2 and reduces the risk of cooling oil in the generator cavity leaking through the connection position between the engine and the generator.

[0061] In one possible design, the sealing end plate 5 is directly clamped and fixed by the engine block and the generator housing to simplify the connection between the sealing end plate 5 and the generator and engine. This helps to reduce the size of the sealing end plate 5, the generator housing and the engine block, and also helps to reduce the gap between the engine and the generator, thus facilitating the miniaturization design of the range extender system.

[0062] In another possible design, as shown in Figure 5, the cylinder block 11 of the engine 1 and the housing 21 of the generator 2 are fixedly connected by a first fastener 6. The first fastener 6 includes, but is not limited to, screws, bolts, pins and other structures. The specific structure and type of the first fastener 6 are not specifically limited in this embodiment. Referring again to Figure 6, a first through hole 521 for the first fastener 6 to pass through is provided at the connection part 52. That is, one end of the first fastener 6 passes through the housing 21 of the generator 2 and the first through hole 521 on the sealing end plate 5 in sequence and then extends into the cylinder block 11 of the engine 1 and is screwed and fixed.

[0063] In this embodiment, a portion of the first fastener 6 is located within the first through hole 521. The first fastener 6 can limit the sealing end plate 5, thereby reducing the risk of displacement or even detachment from the generator 2 and engine 1 during the installation, transportation, and use of the range extender system. This further improves the connection stability between the sealing end plate 5 and the engine 1 and generator 2, which in turn helps to improve the sealing performance of the connection position between the engine 1 and generator 2, thereby reducing the risk of cooling oil leakage.

[0064] As shown in Figure 6, the main body 51 includes a first body 511 and a second body 512. The second body 512 is located between the first body 511 and the connecting part 52. One end of the second body 512 is connected to the connecting part 52, and the other end of the second body 512 is connected to the first body 511. The second body 512 is inclined along the distribution direction of the engine 1 and the generator 2, that is, the first body 511, the second body 512 and the connecting part 52 form a trapezoidal structure. The channel 511A for the crankshaft 12 is located on the first body 511. In the distribution direction X of the engine 1 and the generator 2, the first body 511 abuts against the cylinder 11. The first body 511 and the cylinder 11 are fixedly connected by a second fastener 7. As shown in Figure 6, the first body 511 is provided with a second through hole 513. One end of the second fastener 7 passes through the second through hole 513 and extends into the cylinder 11 to be screwed and fixed.

[0065] In this embodiment, the connecting portion 52 of the sealing end plate 5 is clamped by the cylinder block 11 of the engine 1 and the housing 21 of the generator 2. Simultaneously, the first body 511 abuts against the cylinder block 11 of the engine 1. This reduces the risk that the forces exerted on the sealing end plate 5 by the engine 1 and generator 2 are concentrated at the connecting portion 52, thereby reducing the risk of damage to the connecting portion 52 during the operation of the range extender system and extending the service life of the sealing end plate 5. The fixed connection between the first body 511 and the cylinder block 11 further enhances the stability of the connection between the sealing end plate 5 and the engine 1 and generator 2, which in turn improves the sealing performance of the connection between the engine 1 and generator 2, thus reducing the risk of coolant leakage.

[0066] Figure 7 is a partially enlarged view of the connection position of generator 2, engine 1 and sealing end plate 5. As shown in Figure 7, the range extender system also includes a first seal 9. Along the distribution direction X of engine 1 and generator 2, the first seal 9 is located between sealing end plate 5 and housing 21, and along the radial direction of sealing end plate 5, the first seal 9 is located inside cylinder block 11. Specifically, the first seal 9 is sleeved in the area between the first fastener 6 and the channel 511A. That is, the first seal 9 can reduce the risk of cooling oil inside generator 2 entering engine 1 through the gap between housing 21 and sealing end plate 5 and the first fastener 6, and reduce the risk of cooling oil inside generator 2 overflowing to the outside through the gap between housing 21 and sealing end plate 5, thereby improving the sealing of the connection position between engine 1 and generator 2, and thus reducing the risk of cooling oil leakage.

[0067] The first sealing element can be a sealing strip, sealant, steel gasket, silicone, etc. The embodiments of this application do not impose special limitations on the specific material and structure of the first sealing element.

[0068] The range extender system provided in this application embodiment is a direct-drive range extender system, meaning the output crankshaft is directly connected to the rotor. Figure 8 is a partially enlarged view of the connection position of the generator 2, engine 1, and sealing end plate 5. As shown in Figure 8, the output crankshaft 12 and rotor 23 are directly connected via a third fastener 8, eliminating the flywheel structure and thus reducing the distance between the generator 2 and engine 1. Along the distribution direction X of engine 1 and generator 2, the axial dimension of the range extender system is reduced, which is beneficial for achieving low-cost, miniaturized, and lightweight development of the range extender. In this case, the stability of the range extender system can be improved by adding structures such as a dual-clutch transmission and planetary gear sets.

[0069] In any of the above embodiments, as shown in Figure 8, the range extender system further includes a second seal, which is a first oil seal 1A. The first oil seal 1A can be a commonly available oil seal structure, and the specific structure of the first oil seal 1A will not be described in detail here. The first oil seal 1A is located in the channel 511A of the sealing end plate 5. Along the radial direction of the sealing end plate 5, one side of the first oil seal 1A abuts against the side wall of the channel 511A, and the other side of the first oil seal 1A abuts against the output crankshaft 12.

[0070] In this embodiment, the first oil seal 1A can seal the gap between the output crankshaft 12 and the sealing end plate 5, thereby reducing the risk of cooling oil in the generator 2 entering the outside or the engine 1 through the gap between the output crankshaft 12 and the sealing end plate 5, thus improving the sealing performance of the connection between the engine 1 and the generator 2. In addition, during the rotation of the output crankshaft 12, the temperature of the output crankshaft 12 and the first oil seal 1A rises due to friction. Since the first oil seal 1A has good thermal conductivity, it can conduct the heat generated by the friction between the output crankshaft 12 and the first oil seal 1A to the housing 21, the sealing end plate 5, and the air. The gap between the output crankshaft 12 and the sealing end plate 5 is sealed by the first oil seal 1A, thereby reducing the risk of the second seal being damaged by high temperature under the rotational friction of the output crankshaft 12, and giving the second seal a longer service life.

[0071] Figure 9 is a cross-sectional view of the sealing end plate 5 in one embodiment. The first body 511 includes an oil seal mounting portion 511B, which extends toward the housing 21 along the distribution direction X of the engine 1 and the generator 2. The oil seal mounting portion 511B forms a channel 511A. Referring again to Figure 8, the first oil seal 1A abuts against the oil seal mounting portion 511B along the radial direction of the sealing end plate 5.

[0072] In this embodiment, when the thickness of the sealing end plate 5 is small, the oil seal mounting portion 511B extending along the distribution direction of the engine and generator is provided. This increases the length of the channel 511A, ensuring that the length of the channel 511A meets the installation size requirements of the first oil seal 1A. This reduces the risk that the first oil seal 1A may be difficult or even impossible to install due to the small length of the channel 511A. Furthermore, while ensuring that the length of the channel 511A meets the installation size requirements of the first oil seal 1A, the thickness of the edge of the sealing end plate 5 can be reduced, thereby helping to reduce the overall weight of the sealing end plate 5 and the range extender system.

[0073] Referring again to Figure 8, the engine is equipped with a second oil seal 1B. The second oil seal 1B is a common oil seal structure on the market. The specific structure of the second oil seal 1B will not be described in detail here. Along the radial direction of the output crankshaft 12, that is, along the distribution direction X of the engine 1 and the generator 2, the second oil seal 1B is located between the output crankshaft 12 and the cylinder block 11. At least a part of the second oil seal 1B is located in the mounting hole 15. One side of the second oil seal 1B abuts against the cylinder block 11, and the other side of the second oil seal 1B abuts against the output crankshaft 12.

[0074] Since the second oil seal can seal the gap between the output crankshaft and the cylinder block, and the first oil seal can seal the gap between the output crankshaft and the sealing end plate, there is a significant risk of pressure difference between the cavity between the first and second oil seals and the outside environment during the operation of the range extender system. Along the distribution direction X of the engine and generator, if there is a pressure difference on both sides of the first oil seal and the second oil seal, the first and second oil seals are prone to deformation and failure under the pressure difference. To solve this problem, as shown in Figure 10, which is a structural schematic diagram of the sealing end plate 5 in one embodiment, the sealing end plate 5 is provided with a first ventilation channel 53 extending radially. The number of first ventilation channels 53 is one. Alternatively, as shown in Figure 11, which is a left view of the sealing end plate 5, multiple first ventilation channels 53 are arranged circumferentially along the sealing end plate 5. Furthermore, as shown in Figure 12, which is a structural schematic diagram of the cylinder block 11 of the engine 1 in one embodiment, the cylinder block 11 is provided with at least one second ventilation channel 111.

[0075] Figure 13 is a cross-sectional view of the cylinder body and the sealing end plate at the first ventilation channel and the second ventilation channel. As shown in Figure 13, the cylinder body 11 and the sealing end plate 5 form a first cavity 14, and the first oil seal 1A, the second oil seal 1B, the sealing end plate, the cylinder body and the output crankshaft form a second cavity 1C. In this embodiment, the second cavity 1C is connected to the first cavity 14 through the first ventilation channel 53, and the first cavity 14 is connected to the outside through the second ventilation channel 111. The second cavity is connected to the outside through the first ventilation channel, the first cavity and the second ventilation channel to balance the pressure on both sides of the first oil seal 1A and the second oil seal 1B, thereby reducing the deformation and failure of the first oil seal 1A and the second oil seal 1B under the action of pressure difference, and improving the sealing performance between the cylinder body 11 and the output crankshaft 12.

[0076] In this embodiment, the second venting channel is located at the radial edge of the cylinder block. As shown in FIG12, the cylinder block 11 includes a body 112 and a mounting portion 113. The mounting portion 113 is located on the outer periphery of the body 112. The body 112 and the sealing end plate form the first cavity. The mounting hole 15 for the output crankshaft to pass through is provided in the body 112. The mounting portion 113 is connected to the housing. The second venting channel 111 is provided in the mounting portion 113 and penetrates the mounting portion 113 radially, thereby connecting the first cavity with the outside. By providing the second venting channel 111 on the mounting portion 113 for connection with the housing 21, the housing 21 can cover a portion of the second venting channel 111, thereby reducing the area of ​​the second venting channel 111 exposed to the outside, and thus reducing the risk of external liquid entering the range extender system through the second venting channel 111.

[0077] As shown in Figure 13, the first ventilation channel is disposed on the side surface of the sealing end plate facing the cylinder body, thereby connecting the first ventilation channel with the first cavity.

[0078] In other embodiments, the first ventilation channel can be directly connected to the second ventilation channel, thereby enabling the second cavity to communicate with the outside world through the first and second ventilation channels.

[0079] Figure 13 is a partial enlarged view of the structure of the second ventilation channel 111. In another embodiment, as shown in Figure 13, the outline shape of the second ventilation channel 111 is S-shaped, Z-shaped, or other bent shape. That is, when there is liquid such as condensate or rainwater on the outside of the cylinder block 11, the side wall of the second ventilation channel 111 can block at least part of the liquid, thereby reducing the risk of external liquid entering the engine 1 through the second ventilation channel 111, and also reducing the risk of external liquid entering the space between the cylinder block 11 and the sealing end plate 5 through the second ventilation channel 111 and the first ventilation channel 53. This further reduces the risk of external liquid entering the generator 2 through the gap between the sealing end plate 5 and the housing 21, thereby improving the waterproof performance of the range extender system. In addition, when the range extender system is installed and fixed on the vehicle frame, the second ventilation channel is located at the lower end of the cylinder block. When there is condensate between the cylinder block and the sealing end plate, the condensate can enter the second ventilation channel and flow along the side wall of the second ventilation channel under the action of gravity until it is discharged to the outside, thereby reducing the accumulation of condensate inside the range extender system.

[0080] The number of second ventilation channels can be one or more, as long as they can connect the cavity to the outside. In this embodiment, the specific number of first ventilation channels is not limited. In this embodiment, the number of second ventilation channels is one.

[0081] In summary, referring to Figure 4, the installation process of the range extender system provided in this application is as follows:

[0082] The first oil seal 1A is pressed and fixed onto the hole 511A of the sealing end plate 5;

[0083] The sealing end plate 5 is installed and fixed to the cylinder block 11 of the engine using the second fastener;

[0084] The generator rotor 23 is mounted on the engine output crankshaft 12;

[0085] Install the first seal 9 on the sealing end plate 5;

[0086] The generator housing 21 is mounted to the engine cylinder block 11 by a ring of flange bolts, so that the sealing end plate 5 and the first seal 9 are clamped and fixed by the housing 21 and the cylinder block 11.

[0087] In this embodiment, the generator and engine are separated by a sealing end plate, the gap between the generator housing and the sealing end plate is sealed by a first seal, and the shaft connection position of the range extender system is sealed by a first oil seal and a second oil seal. This improves the sealing performance of the connection position between the engine and the generator, thereby reducing the risk of cooling oil leaking to the outside through the gap between the engine and the generator. This improves the stability of the generator's heat dissipation effect and reduces the risk of functional degradation or even failure of the generator, range extender system, and range-extended vehicle due to high generator temperature.

[0088] For the same or similar parts among the various embodiments in this specification, please refer to each other.

Claims

1. A range extender system, characterized in that, The range extender system includes: A generator, comprising at least a housing, a stator, and a rotor, wherein the stator and the rotor are both mounted in the housing and located within a cavity enclosed by the housing; An engine, the engine including at least a cylinder block and an output crankshaft, the cylinder block being connected to the housing, and along the distribution direction of the engine and the generator, one end of the output crankshaft extending out of the cylinder block through a mounting hole in the cylinder block, and the other end being directly connected to the rotor; A sealing end plate is provided with a channel for the output crankshaft to pass through. Along the distribution direction of the engine and the generator, the sealing end plate is located between the engine and the generator, and the sealing end plate is used to seal the gap between the generator and the engine.

2. The range extender system according to claim 1, characterized in that, The sealing end plate includes a body portion and a connecting portion. Along the radial direction of the sealing end plate, the connecting portion is located outside the body portion, and the connecting portion is clamped by the housing and the cylinder body.

3. The range extender system according to claim 2, characterized in that, The housing and the cylinder are fixedly connected by a first fastener, and a first through hole is provided at the connection part for the first fastener to pass through.

4. The range extender system according to claim 2, characterized in that, The main body includes a first body and a second body. The second body is located between the first body and the connecting part. One end of the second body is connected to the connecting part, and the other end of the second body is connected to the first body. The second body is inclined along the distribution direction of the engine and the generator. The channel is located on the first body. In the distribution direction of the engine and the generator, the first body abuts against the cylinder block and is fixedly connected by a second fastener.

5. The range extender system according to any one of claims 2 to 4, characterized in that, The range extender system also includes a first seal located between the sealing end plate and the housing, and the first seal is located inside the cylinder.

6. The range extender system according to any one of claims 1 to 4, characterized in that, The range extender system also includes a first oil seal located within the channel along the radial direction of the sealing end plate. One side of the first oil seal abuts against the sidewall of the channel, and the other side of the first oil seal abuts against the output crankshaft.

7. The range extender system according to claim 6, characterized in that, The first body includes an oil seal mounting portion, which extends toward the housing along the distribution direction of the engine and the generator, and forms the channel. Along the radial direction of the sealing end plate, the first oil seal abuts against the oil seal mounting portion.

8. The range extender system according to claim 6, characterized in that, The engine includes a second oil seal, at least a portion of which is located within the mounting hole and radially along the output crankshaft, one side of which abuts against the cylinder block and the other side of which abuts against the output crankshaft; The cylinder body and the sealing end plate form a first cavity, and a second cavity is provided between the first oil seal and the second oil seal; The sealing end plate is provided with a first ventilation channel, and the second cavity is connected to the first cavity through the first ventilation channel. The cylinder is provided with a second ventilation channel, and the first cavity is connected to the outside through the second ventilation channel.

9. The range extender system according to claim 8, characterized in that, The first exhaust passage is located on the side of the sealing end plate facing the cylinder body; The cylinder body includes a main body and a mounting part. The mounting part is located on the outer periphery of the main body. The mounting part and the sealing end plate form the first cavity. The mounting part is connected to the housing. The second ventilation channel is disposed in the mounting part and passes through the mounting part radially along the cylinder body.

10. The range extender system according to claim 9, characterized in that, The outline of the second ventilation channel is bent.

11. A range-extended electric vehicle, characterized in that, The range-extended electric vehicle includes: Frame; A power system mounted on the vehicle frame, the power system comprising at least a battery, an electric motor, and a range extender system as described in any one of claims 1 to 10, the electric motor being connected to the battery and used to drive the range-extended vehicle, and a generator being connected to the battery and used to supply power to the battery.

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