Extended-range vehicle body and manufacturing method therefor

Abstract

The present application relates to an extended-range vehicle body and a manufacturing method therefor. The vehicle body comprises a front compartment assembly, a floor assembly, and a range extender assembly. The front compartment assembly is provided with a first mounting and a second mounting. The floor assembly comprises a central tunnel; the central tunnel is provided with a third mounting; and the third mounting is spaced apart from the first mounting and the second mounting in both front-rear and up-down directions. A floor assembly blank is subjected to drawing forming to form a floor body and the central tunnel, and material-storage protrusions are formed on the central tunnel; the floor blank is subjected to shaping processing; and the arc length of each material-storage protrusion is equal to the arc length of a corresponding curved corner. By means of the structure and the manufacturing method, the assembly positional tolerance is reduced to within 2 mm, the amplitude of the range extender assembly during driving is reduced, the vehicle failure rate is reduced by 20%, and noise is reduced by 3 dB. The range extender assembly manufactured by means of the method can be adapted to multiple vehicle models; the utilization rate of the interior space of a vehicle is increased; the passenger compartment space is increased by 170 mm; the system modal frequency is increased to 316 Hz; and the support strength of the range extender assembly is increased by 30%.

Description

Extended-range automobile body and manufacturing method thereof

[0001] The present application claims priority to Chinese Patent Application No. 202411277628.6, filed on September 12, 2024, entitled "Vehicle" and Chinese Patent Application No. 202511080058.6, filed on August 1, 2025, entitled "Extended-range automobile body and manufacturing method thereof", the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0002] The present application relates to the technical field of vehicles, in particular to an extended-range automobile body and a manufacturing method thereof. BACKGROUND

[0003] With the improvement of environmental awareness and the pursuit of energy sustainability, the new energy vehicle market is booming. Extended-range automobiles, with their unique advantages such as longer driving range, lower energy consumption, and excellent driving experience, are gradually emerging in the market and gaining more and more consumers' favor. In the key components of extended-range automobiles, the range extender assembly plays a crucial role. As the power generation core of the vehicle, it provides a solid guarantee for the vehicle's power supply, and its performance and stability directly affect the vehicle's driving performance and user experience.

[0004] In the prior art, the mounting structure of the range extender assembly has been the focus of the industry. For example, the patent document with publication number CN208702594U proposes an integrated motor structure with a starter, which connects the engine output end and the motor shell through a connecting plate, and the front end of the rotor support is connected with the end face of the engine output shaft. However, this scheme has the defect of a relatively long overall length of the motor, which not only leads to difficulties in arranging in the limited front engine compartment space of the vehicle, but also increases the overall vehicle weight, affecting energy utilization efficiency. In addition, the patent document with publication number CN215971079U focuses on the suspension structure of the range-extending hybrid box. This patent attempts to solve some problems through a specific suspension design, but still has shortcomings. Although this suspension structure considers vibration damping to some extent, due to its relatively complex design, it requires more components to achieve the expected function, which not only increases the manufacturing cost, but also increases the difficulty of maintenance and repair. Internationally, there are also some patent technologies related to range extender assemblies, such as the German patent with publication number DE102009057693A. This patent relates to a hybrid electric vehicle, and the connection method of the range extender and the vehicle chassis is relatively traditional, mainly using rigid connection. Although it ensures the stability of the connection, the vibration damping effect is poor. When the vehicle drives on bumpy roads, the vibration generated by the range extender will be directly transmitted to the vehicle body, not only reducing the ride comfort, but also possibly causing the vehicle body related components to loosen, wear out, and other situations, affecting the reliability of the vehicle.

[0005] In summary, in the related prior art, due to the generally large volume of the range extender assembly in the range-extending vehicle, the range extender assembly is prone to large displacement or rotation during vehicle driving, causing large vibration amplitude, which easily affects the vehicle body and cab, seriously affecting the ride comfort inside the vehicle, and also possibly causing long-term damage to the vehicle body structure, reducing the overall safety and durability of the vehicle. Therefore, how to optimize the mounting structure of the range extender assembly to reduce its displacement, rotation and vibration during vehicle driving, and maintain the stability and reliability of the range extender assembly operation, has become a technical problem that needs to be solved.

[0006] Application content

[0007] The present application provides a range-extending vehicle body and a manufacturing method thereof, which solves the problem that the range extender assembly of the range-extending vehicle is prone to large displacement or rotation during driving, causing large vibration amplitude, which easily affects the vehicle body and cab.

[0008] To achieve the above purpose, the main technical solution adopted by the present application includes:

[0009] The first aspect of the embodiment of the present application provides a range-extender vehicle body, comprising a front engine compartment assembly, a floor assembly and a range-extender assembly, the front engine compartment assembly is provided with a first suspension and a second suspension, the first suspension and the second suspension are spaced apart in the left-right direction, the floor assembly is located behind the front engine compartment assembly, the floor assembly comprises a floor body and a middle channel provided on the floor body, the middle channel is provided with a third suspension, the third suspension is spaced apart from the first suspension and the second suspension in the front-rear direction respectively, and the third suspension is also spaced apart from the first suspension and the second suspension in the up-down direction respectively, and the range-extender assembly is fixed on the front engine compartment assembly and the floor assembly through the first suspension, the second suspension and the third suspension.

[0010] Since the first suspension, the second suspension and the third suspension can jointly form a triangular structure to fix the range-extender assembly, on the one hand, the design of the triangular suspension can make the three suspension points be more evenly arranged around the range-extender assembly, forming a stable triangular support structure, which can effectively resist the torsion and vibration of the range-extender assembly from the vehicle driving process, thereby maintaining the stability and reliability of the range-extender assembly operation, improving the safety and reliability of the vehicle, on the other hand, the triangular suspension can also attenuate the vibration of the range-extender assembly during operation, reduce the influence of the vibration of the range-extender assembly on other components of the range-extender vehicle body, improve the noise of the range-extender vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range-extender vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0011] The third suspension is spaced apart from the first suspension and the second suspension in the up-down direction, which can improve the stability and maneuverability of the vehicle, and is conducive to inhibiting the longitudinal vibration of the range-extender assembly. Such a layout is conducive to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range-extender vehicle body and the cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0012] In addition, the range-extender assembly in the embodiment of the present application can be assembled with the first suspension, the second suspension and the third suspension, and finally integrated and installed on the front engine compartment assembly and the floor assembly, so that the relative position of the mounting point in the free state meets the composite position accuracy requirement, the position tolerance in the assembly process is reduced, and the position accuracy of the range-extender assembly is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range-extender assembly.

[0013] Optionally, the third suspension comprises a bushing seat, an elastic member and an inner core, the elastic member is installed in the bushing seat, and the inner core is installed in the elastic member; the inner core is provided with a first mounting hole, the middle channel is provided with a third suspension mounting bracket, and the third suspension mounting bracket is provided with a second mounting hole; and the second mounting hole is connected with the first mounting hole through a mounting bolt.

[0014] The first mounting hole on the inner core of the third suspension is connected with the second mounting hole on the third suspension mounting bracket through a mounting bolt, the connection strength is high, the structure is simple, and the implementation is convenient. The elastic member arranged between the bushing seat and the inner core can adaptively reduce the jitter of the range extender assembly during the operation of the range extender assembly, thereby playing a good buffering effect in the vibration process of the range extender assembly, reducing the influence of the vibration of the range extender assembly on the range extended vehicle body, improving the stability of the range extended vehicle body, and avoiding the collision between the inner core and the bushing seat during the operation of the range extender assembly, and reducing noise.

[0015] Optionally, the diameter of the first mounting hole is greater than the diameter of the mounting bolt, and / or the center position of the first mounting hole is lower than the center position of the second mounting hole in the up-down direction.

[0016] The diameter of the first mounting hole is greater than the diameter of the mounting bolt, so that the mounting bolt has a certain displacement in the first mounting hole in the up-down direction, so that after the subsequent range extender assembly is assembled, the third suspension can be pulled downward by the weight of the range extender assembly itself, so that the mounting bolt is attached to the inner wall surface of the first mounting hole. In addition, the diameter of the first mounting hole is greater than the diameter of the mounting bolt, which facilitates the matching installation of the mounting bolt, reduces the installation difficulty of the mounting bolt, and avoids improving the installation convenience.

[0017] After the range extender assembly is assembled, the third suspension can be pulled downward by the weight of the range extender assembly itself, so that the mounting bolt is attached to the inner wall surface of the first mounting hole, the structural stability is improved, and the third suspension can be driven to a more accurate installation position, the installation precision of the third suspension is improved, and position interference between the third suspension and other components is avoided.

[0018] Optionally, the elastic member comprises a mounting portion and a connecting arm, one end of the connecting arm is connected with the inner wall of the bushing seat, and the other end of the connecting arm is connected with the mounting portion; the mounting portion comprises a mounting cavity, and the inner core is installed in the mounting cavity.

[0019] The inner core is arranged in the mounting cavity of the mounting portion, and the stability of the connection between the inner core and the elastic member can be improved. After the range extender assembly is assembled, the inner core is displaced due to vibration of the range extender assembly, the connecting arm connected to the bushing seat and the mounting portion can provide a reverse tension and a buffering force for the inner core, and the vibration of the range extender assembly is adaptively reduced in the process of operation of the range extender assembly, so that the vibration amplitude of the inner core and the range extender assembly is avoided from being too large, thereby achieving a good buffering effect in the process of vibration of the range extender assembly.

[0020] Optionally, the inner core comprises a first arc surface, a second arc surface and a connecting surface connected between the first arc surface and the second arc surface; the diameter of the first arc surface is greater than the diameter of the second arc surface, and the connecting arm is connected to the corresponding positions of the second arc surface and the connecting surface on the mounting portion.

[0021] The diameter of the first arc surface is relatively large, so that the inner core has sufficient volume to form corresponding positioning holes and mounting holes, the overall strength of the inner core is improved, the inner core is prevented from being damaged by stress, and the structural stability of the third suspension is improved. In addition, the diameter of the second arc surface is relatively small compared with the first arc surface, and the connecting arm is connected to the corresponding positions of the second arc surface and the connecting surface on the mounting portion, so that the volume of the connecting arm is improved, the buffering effect of the connecting arm is improved, the connecting area of the connecting arm and the corresponding inner core on the mounting portion is improved, the stress of the inner core on the connecting arm is prevented from being too concentrated, the fatigue durability of the connecting arm is improved, and the service life of the elastic member is prolonged.

[0022] Optionally, the elastic member further comprises a first buffering portion and a second buffering portion, the first buffering portion forms a first gap between the connecting arm and the mounting portion, and the second buffering portion forms a second gap between the connecting arm and the mounting portion, and the first gap and the second gap are arranged in a vertical direction.

[0023] The first gap and the second gap can provide a buffering space for the vibration of the inner core with the range extender assembly, further reduce the force transmitted to the first buffering portion and the second buffering portion by the inner core, improve the buffering effect, reduce the influence of the vibration of the range extender assembly on the range-extended vehicle body, and improve the stability of the range-extended vehicle body.

[0024] Optionally, the third suspension further comprises a second main plate, one end of the second main plate is connected to the bushing seat, and the other end of the second main plate is provided with a mounting surface connected to the range extender assembly.

[0025] The mounting surface on the second main plate is connected to the range extender assembly, the connecting area of the third suspension and the range extender assembly can be increased, the connecting strength of the third suspension and the range extender assembly is improved, the shaking between the range extender assembly and the third suspension is reduced, and the structural stability of the range-extended vehicle body is improved.

[0026] Optionally, the thickness of the second main plate is 4mm-5mm.

[0027] When the thickness of the second main plate is 4mm-5mm, the thickness of the second main plate is moderate, the volume is small, and it is not easy to interfere with other components. And the second main plate has appropriate static stiffness and dynamic stiffness, which can ensure that the second main plate has good supporting and fixing effect on the range extender assembly, is not easy to resonate with the range extender assembly, reduces the influence on the range extended car body and the car body, and also reduces the risk of cracks or fractures of the second main plate, prolongs the service life. In addition, the second main plate also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the third suspension, and improve the comfort of driving and riding.

[0028] Optionally, the first suspension and the second suspension each include a suspension body, a connecting plate, a first main plate, and a nut plate, one end of the suspension body is connected with the front engine compartment assembly, the other end is connected with the first main plate through the connecting plate, the nut plate is arranged on the first main plate, and the range extender is connected through bolts.

[0029] The suspension body of the first suspension and the second suspension is connected with the first main plate through the connecting plate, which is simple in structure, stable in connection, and easy to prepare and process each part, easy to assemble, and low in cost. The setting of the nut plate can avoid deformation of the first main plate when the first suspension and the second suspension are connected with the range extender assembly, and improve the structural stability of the first main plate. And the setting of the nut plate can also avoid the first main plate being too thick, which increases the preparation cost and reduces the vibration isolation effect, and improves the NVH performance of the vehicle.

[0030] Optionally, the thickness of the first main plate is 4mm-5mm; and / or, the thickness of the nut plate is 3.5mm-4.5mm; and / or, the thickness of the connecting plate is 4mm-5mm.

[0031] When the thickness of the first main plate is 4mm-5mm, and / or the thickness of the nut plate is 3.5mm-4.5mm, and / or the thickness of the connecting plate is 4mm-5mm, the thickness of the first main plate, the nut plate and / or the connecting plate is moderate, the overall structure formed is small in size and is not prone to interference with other components. Moreover, the first main plate, the nut plate and / or the connecting plate have appropriate static stiffness and dynamic stiffness, which can ensure that the overall structure formed by the first main plate, the nut plate and the connecting plate has a good supporting and fixing effect on the range extender assembly, is not prone to resonance with the range extender assembly, reduces the impact on the range extended vehicle body and the vehicle cabin, and also reduces the risk of cracking or breaking, thereby prolonging the service life. In addition, the overall structure formed by the first main plate, the nut plate and the connecting plate also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the first and second suspensions, thereby improving the comfort of driving and riding.

[0032] Optionally, the floor assembly further comprises a first floor cross beam extending in the left-right direction, and at least a portion of the first floor cross beam is fixedly attached to the lower side of the center tunnel, and the third suspension is arranged on the first floor cross beam.

[0033] The third suspension is arranged on the first floor cross beam, and the third suspension is connected with the range extender assembly, so that part of the gravity of the range extender assembly is borne by the first floor cross beam. Compared with arranging the third suspension directly on the floor body, arranging the third suspension on the first floor cross beam can greatly reduce the stress on the floor body. Moreover, the first floor cross beam can significantly increase the structural strength of the center tunnel, and the third suspension is directly connected with the first floor cross beam instead of being directly connected with the center tunnel, which can improve the installation stability of the range extender assembly. In addition, the first floor cross beam can buffer the vibration generated by the range extender assembly, thereby improving the overall shock absorption performance of the vehicle, and further greatly improving the use comfort of the user. For example, the first floor cross beam can increase the structural strength of the center tunnel by 20%, thereby ensuring the structural stability of the floor body.

[0034] Optionally, the first floor cross beam comprises a first body portion, a second body portion, and a protruding portion connected between the first body portion and the second body portion, the protruding portion protrudes upward compared with the first body portion and the second body portion, wherein the protruding portion is fixedly attached to the lower side of the center tunnel, and the first body portion and the second body portion are both fixedly attached to the floor body; and the third suspension is arranged on the protruding portion.

[0035] The protruding portion is fixedly attached to the lower side of the center tunnel, and the first body portion and the second body portion are both fixedly attached to the floor body, which can reduce the single-point stress on the floor body, reduce the risk of stress concentration on the floor body, improve the service life of the floor body, and further improve the service life of the vehicle.

[0036] Optionally, the first body part and the second body part each comprise a first connecting part and a second connecting part, and the first connecting part is connected between the protruding part and the second connecting part.

[0037] The first body part and the second body part each comprise a first connecting part and a second connecting part, so that the first connecting part, the second connecting part and the protruding part can be manufactured respectively, facilitating replacement of the first connecting part, the second connecting part or the protruding part, improving the design freedom of the first floor beam, so that the first floor beam can be applied to different vehicle models, and the use range of the first floor beam is improved.

[0038] In addition, the structural strength of the first connecting part, the second connecting part and the protruding part can be set to be different, so that the first floor beam assembled has a variable strength structure, so that the structural strength of the first floor beam can be adjusted according to the stress condition of the first floor beam in different positions, so as to reduce the overall weight of the first floor beam and save costs.

[0039] Optionally, the first connecting part comprises a first bending section and a second bending section which are oppositely bent, the first bending section is connected with the protruding part, and the second bending section is connected with the second connecting part.

[0040] The first connecting part comprises a first bending section and a second bending section which are oppositely bent, which can improve the connection area of the first connecting part with the protruding part and the second connecting part, and improve the connection strength of the connecting parts of each component, so as to improve the structural stability of the first floor beam.

[0041] Optionally, the material strength of the protruding part is higher than that of the first connecting part and the second connecting part, or the thickness of the protruding part is greater than that of the first connecting part and the second connecting part.

[0042] The structural strength of the protruding part is higher than that of the first connecting part and the second connecting part, so that the supporting effect of the protruding part on the center channel can be improved, so as to ensure the structural stability of the floor assembly. When the material strength of the protruding part is higher than that of the first connecting part and the second connecting part, the structural strength of the protruding part can be ensured to be higher than that of the first connecting part and the second connecting part, so that the supporting effect of the protruding part on the center channel can be improved, and at the same time, the thickness of the protruding part can be made thinner, so as to reduce the space occupied by the protruding part and improve the space utilization of the center channel. When the thickness of the protruding part is greater than that of the first connecting part and the second connecting part, the structural strength of the protruding part can be higher than that of the first connecting part and the second connecting part, so as to ensure the supporting effect of the protruding part on the center channel.

[0043] Optionally, the first floor beam is symmetrically arranged in the left-right direction.

[0044] The first floor cross beam is symmetrically arranged in the left-right direction, which can realize the modularization of the first floor cross beam, so that the first floor cross beam moves in the middle channel of the floor body in the front-rear direction, so that the first floor cross beam can adapt to different vehicle models, improve the application range of the first floor cross beam, and reduce the development cost.

[0045] Optionally, the floor assembly further comprises a first floor longitudinal beam and a second floor longitudinal beam, both of which are arranged on the floor body and extend in the front-rear direction, and the two ends of the first floor cross beam in the length direction are connected with the first floor longitudinal beam and the second floor longitudinal beam respectively.

[0046] The first floor cross beam is connected with the first floor longitudinal beam and the second floor longitudinal beam in the length direction (left-right direction), and the first floor longitudinal beam and the second floor longitudinal beam can support the first floor cross beam. In addition, the first floor cross beam can greatly improve the force transmission performance of the floor assembly, so that the force of the extended-range vehicle body is quickly transmitted out when the force in the left-right direction is impacted.

[0047] Of course, the first floor cross beam is connected with the first floor longitudinal beam and the second floor longitudinal beam in the length direction (left-right direction), which can further improve the structural strength of the floor assembly, thereby improving the installation stability of the range extender assembly.

[0048] When the range extender assembly operates to generate vibration, the first floor cross beam can disperse the vibration generated by the range extender assembly through the first floor longitudinal beam and the second floor longitudinal beam, reduce the influence of the vibration generated by the range extender assembly on the extended-range vehicle body during operation, and improve the user's comfort.

[0049] Optionally, the front engine compartment assembly comprises a subframe, the subframe is connected with the first floor longitudinal beam and the second floor longitudinal beam respectively, and the first suspension and the second suspension are arranged on the subframe.

[0050] The first floor longitudinal beam and the second floor longitudinal beam can support the subframe. Since the range extender assembly is connected with the subframe through the first suspension and the second suspension, and the subframe is connected with the first floor longitudinal beam and the second floor longitudinal beam, the range extender assembly can be indirectly connected with the first floor longitudinal beam and the second floor longitudinal beam through the subframe, and the installation of the range extender assembly is more free.

[0051] When the range extender assembly operates to generate vibration, the subframe can disperse the vibration generated by the range extender assembly through the first floor longitudinal beam and the second floor longitudinal beam, reduce the influence of the vibration generated by the range extender assembly on the extended-range vehicle body during operation, and improve the user's comfort.

[0052] Optionally, the front cabin assembly further comprises a first front cabin longitudinal beam and a second front cabin longitudinal beam, the first front cabin longitudinal beam extends in the front-rear direction, the second front cabin longitudinal beam extends in the front-rear direction, and the second front cabin longitudinal beam is spaced apart from the first front cabin longitudinal beam in the left-right direction, wherein the sub-frame is further connected to the first front cabin longitudinal beam and the second front cabin longitudinal beam respectively.

[0053] Therefore, the sub-frame not only connects the first floor longitudinal beam and the second floor longitudinal beam together, but also connects the first front cabin longitudinal beam and the second front cabin longitudinal beam together, so that the connection between the front cabin assembly and the floor assembly is more stable, and the installation stability of the range extender assembly is improved.

[0054] The sub-frame is connected to the first front cabin longitudinal beam and the second front cabin longitudinal beam, and when the range extender assembly operates to generate vibration, the sub-frame can disperse the vibration generated by the range extender assembly through the first front cabin longitudinal beam and the second front cabin longitudinal beam, thereby reducing the influence of the vibration generated by the range extender assembly on the body of the range extended vehicle and improving the user's comfort.

[0055] Optionally, the front cabin assembly defines a first accommodation space, the middle channel defines a second accommodation space, the second accommodation space communicates with the first accommodation space, the range extender assembly comprises an engine and a generator, the engine is power-connected to the generator, the engine is located at the front side of the generator, a part of the engine is arranged in the first accommodation space, and the other part of the engine and the generator are arranged in the second accommodation space.

[0056] A part of the range extender assembly is arranged in the first accommodation space defined by the front cabin assembly, and the other part of the range extender assembly is arranged in the second accommodation space defined by the middle channel, so that the range extender assembly can be installed in a front-end smaller vehicle model (a vehicle model with a smaller front end), thereby making the range extender assembly adapt to multiple vehicle models, expanding the application range of the range extender assembly, and improving the utilization rate of the interior space of the body of the range extended vehicle. For example, the structure can shorten the front suspension length of the range extender assembly in the front cabin assembly by more than 170 mm, i.e., the passenger compartment space can be increased by more than 170 mm, thereby improving the utilization rate of the interior space of the body of the range extended vehicle.

[0057] A part of the engine is arranged in the first accommodation space, and the other part of the engine and the generator are arranged in the second accommodation space. Since the front cabin assembly defines the first accommodation space and the second accommodation space is arranged below the floor assembly, the engine generates relatively large noise and vibration when operating. Compared with arranging the engine entirely in the second accommodation space, arranging a part of the engine in the first accommodation space can obviously greatly reduce the influence of the vibration and noise generated by the engine on the passengers, thereby greatly improving the comfort of the vehicle.

[0058] Optionally, the range extender assembly further comprises a generator controller, the generator comprises a first housing, the motor controller comprises a second housing, the range extender assembly further comprises a third housing, the third housing and the first housing jointly define a first space accommodating the rotor, the third housing and the second housing jointly define a second space accommodating the electrical components, the upper side of the first housing is provided with a recessed portion recessed upward, and the first housing is further provided with a plurality of reinforcing ribs, each of which is connected to the inner wall surface of the recessed portion and extends in the front-rear direction.

[0059] The first housing, the second housing and the third housing jointly define an accommodation space accommodating the generator and the generator controller, the generator and the generator controller share the third housing, which can greatly reduce the manufacturing cost of the generator and the generator controller and improve the assembly efficiency of the generator and the generator controller.

[0060] The upper side of the first housing is provided with a recessed portion recessed upward, and a plurality of reinforcing ribs are further arranged on the recessed portion, which can improve the system modal of the vehicle and improve the support strength of the range extender assembly. For example, the system modal of the vehicle can be improved to 316Hz, and the support strength of the range extender assembly can be improved by 30%, thereby improving the overall performance of the vehicle.

[0061] Optionally, the range extender assembly comprises an engine and a generator, the engine and the generator are power-connected, the engine is located at the front side of the generator, the engine has a first power output shaft, the generator has a first power input shaft, the first power output shaft and the second power input shaft are parallel and extend in the front-rear direction.

[0062] That is, the engine and the generator are both installed in the front-rear direction, thereby reducing the occupation of the front engine assembly in the left-right direction.

[0063] The first power output shaft can be arranged above the first power input shaft, the first power output shaft and the first power input shaft are parallel and extend in the front-rear direction, which can make the power of the engine more smoothly transmitted to the generator, improve the overall modal of the vehicle system, and reduce the generation of range extender assembly vibration.

[0064] The range extender further comprises a speed increaser, the speed increaser comprises a first driving gear and a first driven gear meshing with each other, the first driving gear is power-connected with the engine, and the first driven gear is power-connected with the generator, wherein the rotation axis of the first driving gear and the rotation axis of the second driving gear are spaced apart in the up-down direction.

[0065] The rotation axis of the first driving gear and the rotation axis of the first driven gear are spaced apart in the up-down direction, so that the space of the engine compartment in the up-down direction can be fully utilized, the space of the speed increaser in the left-right direction of the engine compartment is reduced, the range of application of the range extender assembly can be expanded, and the range extender assembly can be installed in a vehicle with a smaller front engine compartment assembly.

[0066] The second aspect of the embodiment of the present application provides a manufacturing method of a range-extending vehicle body, which is used to manufacture the range-extending vehicle body described in any of the above embodiments. The manufacturing method of the range-extending vehicle body comprises:

[0067] manufacturing a front engine compartment assembly;

[0068] manufacturing a floor assembly, the floor assembly being provided with a middle channel;

[0069] connecting the floor assembly with the front engine compartment assembly;

[0070] connecting a first suspension, a second suspension and a third suspension with the range extender assembly; wherein the first suspension and the second suspension are spaced apart in the left-right direction, and the third suspension is spaced apart from the first suspension and the second suspension in the up-down direction;

[0071] connecting the first suspension and the second suspension with the front engine compartment assembly, and connecting the third suspension with the middle channel.

[0072] Since the first suspension, the second suspension and the third suspension jointly constitute a triangular structure to fix the range extender assembly, on the one hand, the design of the triangular suspension can make the three suspension points be evenly arranged around the range extender assembly to form a stable triangular support structure, which can effectively resist the torsion and vibration of the range extender assembly from the vehicle driving process, thereby maintaining the stability and reliability of the range extender assembly operation, improving the safety and reliability of the vehicle, and on the other hand, the triangular suspension can also attenuate the vibration of the range extender assembly during operation, reduce the influence of the vibration of the range extender assembly on other components of the range-extending vehicle body, improve the noise of the range-extending vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range-extending vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0073] The third suspension is spaced apart from the first suspension and the second suspension in the up-down direction, that is, the first suspension and the second suspension can be below the third suspension, the third suspension is above the first suspension and the second suspension, that is, the first suspension and the second suspension are arranged below the range extender assembly, and the third suspension is arranged above the range extender assembly, so that the stability and maneuverability of the vehicle are improved, and the mass center distribution of the range extender assembly is more reasonable. Moreover, the suspensions at different positions can be optimally arranged for vibrations in different directions, the first suspension and the second suspension are arranged below the range extender assembly, which is beneficial to horizontal and vertical vibrations of the range extender assembly, and the third suspension is arranged above the range extender assembly, which is beneficial to suppressing longitudinal vibrations of the range extender assembly. Such a layout is beneficial to comprehensively improving the vibration isolation effect, reducing the influence of vibrations on the range extender vehicle body and cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0074] In addition, the range extender assembly in the embodiment of the present application can be assembled with the first suspension, the second suspension and the third suspension, and finally integrated and installed on the front engine compartment assembly and the floor assembly, so that the relative positions of the mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process is reduced, and the position accuracy of the range extender assembly is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

[0075] Optionally, the manufacturing floor assembly specifically comprises:

[0076] A floor blank is manufactured;

[0077] The floor blank is subjected to drawing forming processing to form the floor body and the middle channel, and a storage convex is formed on the middle channel;

[0078] The floor blank is subjected to shaping processing to press down the storage convex to form an arc corner at the connection between the middle channel and the floor body.

[0079] The floor blank is subjected to drawing forming processing to form a floor body and a middle channel, and a storage bump is formed on the middle channel. When the floor blank subjected to the drawing forming processing is shaped, the storage bump can be pressed down to shape the arc corner at the connection between the middle channel and the floor body, so as to form a floor assembly to meet the use requirements of the extended-range automobile body. The manufacturing process is simple and facilitates mass production of the floor assembly. By forming the storage bump on the middle channel when the floor blank is subjected to the drawing forming processing, a stepped structure similar to the stepped structure is formed at the sidewall of the middle channel, so that the overall depth of the middle channel is ensured, the drawing angle is avoided to be too steep, the forming condition is improved, the risk of cracking at the middle channel in the drawing forming process is reduced, the production yield is improved, and the manufacturing cost is saved. For example, the production yield at the middle channel can be improved to 100%, and the risk of cracking at the middle channel in the drawing forming process is avoided.

[0080] Optionally, the arc length of the storage bump is equal to the arc length of the corresponding arc corner.

[0081] When the arc length of the storage bump is equal to the arc length of the corresponding arc corner, the overall thickness of the floor assembly can be uniform when the storage bump is pressed down to shape the arc corner at the connection between the middle channel and the floor body, the risk of wrinkling, folding or cracking at the arc corner is avoided, the production yield is further improved, and the manufacturing cost is saved. BRIEF DESCRIPTION OF DRAWINGS

[0082] In order to more clearly illustrate the specific embodiments of the present application or the technical solutions in the prior art, the following will briefly introduce the drawings needed to be used in the description of the specific embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.

[0083] FIG. 1 is a schematic diagram of part of the structure of an extended-range automobile body in a specific embodiment in the related art;

[0084] FIG. 2 is a schematic diagram of the structure of an extended-range automobile body provided by an embodiment of the present application;

[0085] FIG. 3 is a schematic diagram of the structure of a front engine compartment assembly provided by an embodiment of the present application;

[0086] FIG. 4 is a schematic diagram of the structure of a front engine compartment assembly provided by an embodiment of the present application but excluding an extended-range device assembly;

[0087] FIG. 5 is a bottom view of the front engine compartment assembly provided by an embodiment of the present application;

[0088] FIG. 6 is a schematic diagram of the structure of a front engine compartment assembly provided by an embodiment of the present application but excluding an extended-range device assembly and a floor assembly;

[0089] Fig. 7 is a schematic view of a partial structure of a range-extended vehicle body according to an embodiment of the present application;

[0090] Fig. 8 is a schematic view of the partial structure of the range-extended vehicle body according to an embodiment of the present application from another perspective;

[0091] Fig. 9 is a side view of a third suspension according to an embodiment of the present application;

[0092] Fig. 10 is an enlarged view of a portion of Fig. 9;

[0093] Fig. 11 is a schematic view of the third suspension according to an embodiment of the present application from another perspective;

[0094] Fig. 12 is a schematic view of a first suspension and a second suspension according to an embodiment of the present application;

[0095] Fig. 13 is a schematic view of a partial structure of the first suspension according to an embodiment of the present application;

[0096] Fig. 14 is a schematic view of a partial structure of the second suspension according to an embodiment of the present application;

[0097] Fig. 15 shows the first suspension and the second suspension;

[0098] Fig. 16 shows the third suspension;

[0099] Fig. 17 shows a middle tunnel structure;

[0100] Fig. 18 is a schematic view of a partial structure of a first floor cross beam according to an embodiment of the present application;

[0101] Fig. 19 is a schematic view of a partial structure of a range-extended vehicle body according to another embodiment of the present application;

[0102] Fig. 20 is an exploded view of the partial structure of the first floor cross beam according to an embodiment of the present application;

[0103] Fig. 21 is a schematic view of a partial structure of a floor assembly according to an embodiment of the present application;

[0104] Fig. 22 is a schematic view of a structure of a range extender assembly according to an embodiment of the present application;

[0105] Fig. 23 is an enlarged view of a portion of the range extender assembly according to an embodiment of the present application;

[0106] Fig. 24 is an enlarged view of a portion of the range extender assembly according to an embodiment of the present application;

[0107] Fig. 25 shows the third suspension;

[0108] FIG. 26 is a flow chart of a manufacturing method of a range extender automobile body according to an embodiment of the present application;

[0109] FIG. 27 is a flow chart of a manufacturing method of a floor assembly according to an embodiment of the present application;

[0110] FIG. 28 is a drawing of a drawing forming process of a floor blank of a floor assembly according to an embodiment of the present application;

[0111] FIG. 29 is a drawing of a shaping process of a floor blank of a floor assembly according to an embodiment of the present application.

[0112] Reference signs: range extender assembly 130'; front suspension 116'; rear suspension 127'; automobile body 100; front engine compartment assembly 110; first accommodating space 110A; first suspension 111; second suspension 112; subframe 113; first front engine compartment longitudinal beam 114; second front engine compartment longitudinal beam 115; suspension body 116; connecting plate 117; first main plate 118; nut plate 119; floor assembly 120; floor body 121; middle channel 122; lower side surface 1220; second accommodating space 122A; third suspension 123; bushing seat 1231; elastic member 1232; mounting portion 1232A; connecting arm 1232B; first buffer portion 1232C; second buffer portion 1232D; inner core 1233; first mounting hole 1233A; first arc surface 1233B; second arc surface 1233C; connecting surface 1233D; first gap 1234; second gap 1235; second main plate 1236; mounting surface 1236A; first floor cross beam 124; first body portion 124A; second body portion 124B; protruding portion 124C; first connecting portion 1241; first bending segment 1241A; second bending segment 1241B; second connecting portion 1242; first floor longitudinal beam 125; second floor longitudinal beam 126; third suspension mounting bracket 127; second mounting hole 127A; mounting bolt 128; arc-shaped corner 129; range extender assembly 130; engine 131; first power output shaft 131A; generator 132; first power input shaft 132A; generator controller 133; first housing 140; recessed portion 140A; second housing 141; third housing 142; speed increaser 150; first driving gear 151; first driven gear 152; reinforcing rib 160; battery 170; electric motor 180; fuel tank 190; mounting hole 200; drawing female die 301; drawing male die 302; shaping female die 401; shaping male die 402; floor blank 500; storage protrusion 501; front-rear direction X; left-right direction Y; up-down direction Z. DETAILED DESCRIPTION

[0113] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0114] Unless otherwise defined, all technical and scientific terms used in the present application have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs; the terms used in the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application; the terms "include" and "have" and any variations thereof in the specification and claims of the present application and the above description of drawings are intended to cover non-exclusive inclusion. The terms "first", "second" and the like in the specification and claims of the present application and the above description of drawings are used to distinguish different objects, not to describe a particular order or primary and secondary relationship.

[0115] In the present application, the phrase "embodiment" means that the specific features, structures or characteristics described in connection with the embodiment can be included in at least one embodiment of the present application. The phrase appears at various places in the specification does not necessarily refer to the same embodiment, nor is it necessarily mutually exclusive or alternative embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described in the present application can be combined with other embodiments.

[0116] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mount", "connect", "connection", "attach" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integral connection; it can be direct connection, or indirect connection through intermediate medium, or internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0117] In the present application, the term "and / or" is only a description of the association relationship between the associated objects, which means that there can be three relationships, for example, A and / or B can mean that A exists alone, A and B exist together, and B exists alone. In addition, the character " / " in the present application generally represents an "or" relationship between the front and rear associated objects.

[0118] "Multiple" appearing in the present application means two or more (including two), and similarly, "multiple groups" means two or more groups (including two groups), and "multiple pieces" means two or more pieces (including two pieces).

[0119] With the development of new energy vehicles, the range-extender electric vehicle combines the advantages of pure electric vehicles and fuel vehicles. When the battery power is insufficient, the internal combustion engine will start to charge the battery or directly provide power for the electric motor, thereby greatly extending the cruising range of the electric vehicle. This makes the range-extender vehicle perform well in long-distance travel, reduces the need for frequent charging, and the range-extender vehicle is more and more favored by people. The range-extender assembly includes a generator, an engine, and a generator controller. The range-extender assembly is usually arranged in the front engine compartment assembly.

[0120] In the range-extender vehicle, the range-extender assembly is usually installed in the front engine compartment assembly by a plurality of suspension devices.

[0121] Figure 1 shows a partial structure diagram of a range-extender vehicle body in one embodiment of the related art. As shown in Figure 1, the front suspension 116' and the rear suspension 127' are both located below the range-extender assembly 130', which is supported by the front suspension 116' and the rear suspension 127' to form a lower supporting installation structure. However, due to the large size of the range-extender assembly 130' in the range-extender vehicle, the range-extender assembly 130' is prone to large displacement or rotation during driving due to inertia, resulting in large vibration amplitude, which can affect the range-extender vehicle body and the cab.

[0122] Therefore, the present application provides a range-extender vehicle body and a manufacturing method thereof, which reduces the vibration amplitude of the range-extender assembly during driving, reduces the impact of the range-extender assembly vibration on the range-extender vehicle body and the cab, and improves the noise of the range-extender vehicle body. The vehicle disclosed in the embodiments of the present application can include a range-extender vehicle body, a microcar with few seats (two or four seats), a small car, a compact car, a medium car, a medium-large car, and the like.

[0123] The front engine compartment assembly disclosed in the embodiments of the present application can include a first accommodating space, a first suspension, a second suspension, a subframe, a first front engine compartment longitudinal beam, and a second front engine compartment longitudinal beam.

[0124] The floor assembly disclosed in the embodiments of the present application can include a floor body, a middle channel, a second accommodating space, a third suspension, a first floor transverse beam, a first floor longitudinal beam, and a second floor longitudinal beam.

[0125] The following embodiments are described with reference to a range-extender vehicle body of one embodiment of the present application for convenience of description.

[0126] Please refer to FIG. 2 to FIG. 8, FIG. 2 is a structural schematic diagram of a range-extender automobile body provided by an embodiment of the present application; FIG. 3 is a structural schematic diagram of a front engine compartment assembly 110 provided by an embodiment of the present application; FIG. 4 is a structural schematic diagram of the front engine compartment assembly 110 provided by an embodiment of the present application but not containing a range-extender assembly 130; FIG. 5 is a bottom view of the front engine compartment assembly 110 provided by an embodiment of the present application; FIG. 6 is a structural schematic diagram of the front engine compartment assembly 110 provided by an embodiment of the present application but not containing the range-extender assembly 130 and a floor assembly 120; FIG. 7 shows a side view of the range-extender assembly 130 and the first suspension 111, the second suspension 112 and the third suspension 123; FIG. 8 shows a structural schematic diagram of the range-extender assembly 130 and the first suspension 111, the second suspension 112 and the third suspension 123.

[0127] As shown in FIG. 2 to FIG. 8, the present application provides a range-extender automobile body 100, which can be applied to multiple vehicle models such as the Xingguang series.

[0128] The range-extender automobile body 100 comprises a front engine compartment assembly 110, a floor assembly 120 and a range-extender assembly 130. The front engine compartment assembly 110 is provided with a first suspension 111 and a second suspension 112, which are spaced apart in the left-right direction Y. The floor assembly 120 is located behind the front engine compartment assembly 110. The floor assembly 120 comprises a floor body 121 and a middle channel 122 provided on the floor body 121, and the middle channel 122 is provided with a third suspension 123, which is spaced apart from the first suspension 111 and the second suspension 112 in the front-rear direction X and is also spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z. The range-extender assembly 130 is fixed to the front engine compartment assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0129] The first suspension 111 and the second suspension 112 are provided on the front engine compartment assembly 110, and the third suspension 123 is provided on the middle channel 122. The first suspension 111 and the second suspension 112 are arranged in a first accommodating space 110A, and the third suspension 123 is arranged in a second accommodating space 122A. The first suspension 111 and the second suspension 112 are arranged in front of the third suspension 123, and the third suspension 123 is arranged behind the first suspension 111 and the second suspension 112. The first suspension 111 and the second suspension 112 are spaced apart in the front-rear direction X. The first suspension 111, the second suspension 112 and the third suspension 123 jointly form a triangular structure, and the range-extender assembly 130 is fixed to the front engine compartment assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0130] Since the first suspension 111, the second suspension 112 and the third suspension 123 jointly constitute a triangular structure to fix the range extender assembly 130, on the one hand, the design of the triangular suspension can make the three suspension points be more evenly arranged around the range extender assembly 130, forming a stable triangular support structure, which can effectively resist the torsion and vibration of the range extender assembly 130 from various aspects during the driving of the vehicle, thereby maintaining the stability and reliability of the operation of the range extender assembly 130, improving the safety and reliability of the vehicle, on the other hand, the triangular suspension can also attenuate the vibration generated by the range extender assembly 130 during operation, reduce the influence of the vibration generated by the range extender assembly 130 on other components of the range extended vehicle body 100, improve the noise of the range extended vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range extended vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0131] Fixing the range extender assembly 130 on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension can also realize the independent installation and disassembly of the range extender assembly 130, which is convenient for maintenance and replacement when the range extender assembly 130 fails, which is also conducive to improving the manufacturing and assembly efficiency of the vehicle. Moreover, the layout of the triangular suspension is relatively compact, which can maximize the use of the space inside the range extended vehicle body 100, reduce the interference with other components, and improve the space utilization of the vehicle.

[0132] Fixing the range extender assembly 130 on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension is also conducive to reducing the loss of power during transmission, improving the power output efficiency of the range extender assembly 130, and further improving the overall performance of the vehicle.

[0133] The third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z, that is, the first suspension 111 and the second suspension 112 can be below the third suspension 123, the third suspension 123 is above the first suspension 111 and the second suspension 112, that is, the first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, which improves the stability and maneuverability of the vehicle, and the mass center distribution of the range extender assembly 130 is more reasonable. Moreover, the suspensions at different positions can be optimally arranged for vibration in different directions, the first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, which is conducive to horizontal and vertical vibration of the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, which is conducive to suppressing longitudinal vibration of the range extender assembly 130. Such a layout is conducive to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range extender vehicle body and cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0134] Moreover, the range extender assembly 130 in the embodiment of the present application can be finally integrated and installed on the front engine compartment assembly 110 and the floor assembly 120 after being assembled with the first suspension 111, the second suspension 112 and the third suspension 123, so that the relative positions of the three mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process can be reduced, and the position accuracy of the range extender assembly 130 is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

[0135] In one embodiment, the displacement of the range extender assembly 130 in the front-rear direction X is generally required to be between -15 mm and 15 mm, and the rotation angle of the range extender assembly 130 in the left-right direction Y is generally required to be between -1.5° and 1.5°. As described above, in the related art shown in FIG. 1, when the vehicle is subjected to a front collision or a rear collision at an acceleration between -11 g and 11 g, the maximum positive displacement of the range extender assembly 130' is 15.677 mm, the maximum negative displacement of the range extender assembly 130' is -16.958 mm, the maximum positive rotation angle of the range extender assembly 130' is 1.675°, and the maximum negative rotation angle of the range extender assembly 130' is -1.9°. When the vehicle is subjected to a forward movement or a backward movement at an acceleration between -3 g and 3 g, the maximum positive displacement of the range extender assembly 130' is 12.808 mm, the maximum negative displacement of the range extender assembly 130' is -13.396 mm, the maximum positive rotation angle of the range extender assembly 130' is 1.376°, and the maximum negative rotation angle of the range extender assembly 130' is -1.452°. In this case, the maximum positive displacement and the maximum negative displacement of the range extender assembly 130' when the vehicle is subjected to a front collision or a rear collision at an acceleration between -11 g and 11 g are both outside the range of -15 mm to 15 mm, and the maximum positive rotation angle and the maximum negative rotation angle of the range extender assembly 130' are both outside the range of -1.5° to 1.5°. The displacement is large, which results in a large vibration amplitude, and thus the range extender vehicle body and the cab are easily affected, and the noise is large.

[0136] In the embodiment of the present application, when the vehicle is subjected to a front collision or a rear collision at an acceleration between -11 g and 11 g, the maximum positive displacement of the range extender assembly 130 is 14.8 mm, the maximum negative displacement of the range extender assembly 130 is -13.4 mm, the maximum positive rotation angle of the range extender assembly 130 is 1.48°, and the maximum negative rotation angle of the range extender assembly 130 is -1.15°. When the vehicle is subjected to a forward movement or a backward movement at an acceleration between -3 g and 3 g, the maximum positive displacement of the range extender assembly 130 is 9.9 mm, the maximum negative displacement of the range extender assembly 130 is -9.2 mm, the maximum positive rotation angle of the range extender assembly 130 is 0.89°, and the maximum negative rotation angle of the range extender assembly 130 is -0.69°. As can be seen, the displacement of the range extender assembly 130 in the front-rear direction X and the rotation angle of the range extender assembly 130 in the left-right direction Y are effectively reduced in the vehicle of the embodiment of the present application. That is, the maximum displacement when the vehicle is subjected to a front collision, a rear collision, a forward movement, or a backward movement under the above conditions is between -15 mm and 15 mm, and the maximum rotation angle is between -1.5° and 1.5°. Therefore, the vibration amplitude of the range extender assembly 130 is reduced, the influence of the vibration of the range extender assembly 130 on other components of the range extender vehicle body is reduced, the use comfort of the vehicle is improved, and the noise of the range extender vehicle body is improved. For example, the noise of the range extender vehicle body is reduced by 3 decibels, and the use comfort of the vehicle is improved.

[0137] In some embodiments, the first suspension 111 and the second suspension 112 are arranged below the engine 131, and the third suspension 123 is arranged above the generator 132 or the generator controller 133. Due to the weight, volume and vibration generated during operation of the engine 131, the engine 131 is usually higher than the generator 132. Arranging the first suspension 111 and the second suspension 112 below the engine 131 can increase the support points of the engine 131, thereby greatly improving the stability and reliability of the operation of the engine 131.

[0138] In some embodiments, the first suspension 111, the second suspension 112 and the third suspension 123 can be arranged as rubber suspensions, hydraulic suspensions, semi-active suspensions and active suspensions. Rubber suspensions are made of natural rubber or synthetic rubber and have excellent physical and mechanical properties, sound insulation, vibration isolation and cushioning capacity. Rubber suspensions can be divided into bushing type suspensions, block-shaped rubber suspensions and wedge-shaped rubber suspensions according to structure. Hydraulic suspensions have a decoupling disc / membrane and a flow channel plate forming an inertia passage inside. The hydraulic suspensions can absorb and attenuate vibration through the flow of liquid. Hydraulic suspensions can be divided into cylindrical hydraulic suspensions and trapezoidal hydraulic suspensions according to structure. Hydraulic suspensions have excellent dynamic characteristics and can adapt to different frequency and amplitude requirements for vibration damping and noise reduction. Semi-active suspensions combine an electronic control unit, a solenoid valve and a suspension body with a movable valve (which can be a rubber suspension or a liquid resistance suspension). The stiffness and damping of the suspension are dynamically adjusted by controlling the flow of liquid to adapt to different working conditions. Active suspensions generate dynamic force through actuators to offset the vibration of the engine and achieve more precise vibration control. Active suspensions are composed of passive suspensions (rubber suspensions or liquid resistance suspensions), vibration sensors, controllers and actuators, which can effectively suppress high-frequency vibration and noise.

[0139] FIG. 9 shows a side view of the third suspension.

[0140] As shown in FIGS. 7-9, in a specific embodiment, the third suspension 123 includes a bushing seat 1231, an elastic member 1232 and an inner core 1233. The elastic member 1232 is installed in the bushing seat 1231, and the inner core 1233 is installed in the elastic member 1232. The inner core 1233 is provided with a first mounting hole 1233A. The third suspension mounting bracket 127 is arranged on the middle channel 122, and the third suspension mounting bracket 127 is provided with a second mounting hole 127A. The second mounting hole 127A is connected with the first mounting hole 1233A through the mounting bolt 128.

[0141] In the embodiment, the first mounting hole 1233A on the inner core 1233 of the third suspension 123 is connected with the second mounting hole 127A on the third suspension mounting bracket 127 through the mounting bolt 128, which has high connection strength, simple structure and is easy to realize. The elastic member 1232 arranged between the bushing seat 1231 and the inner core 1233 can adaptively reduce the jitter of the range extender assembly 130 during the working process of the range extender assembly 130, thereby playing a good buffering effect during the vibration of the range extender assembly 130, reducing the influence of the vibration of the range extender assembly 130 on the range-extended vehicle body, improving the stability of the range-extended vehicle body, and avoiding the collision between the inner core 1233 and the bushing seat 1231 during the working process of the range extender assembly 130, thereby reducing the noise.

[0142] In a specific embodiment, as shown in FIGS. 8 and 9, the center position of the first mounting hole 1233A is lower than the center position of the second mounting hole 127A in the up-down direction.

[0143] In the embodiment, after the range extender assembly 130 is assembled, the range extender assembly 130 can be used to pull the third suspension 123 downward, so that the mounting bolt 128 is attached to the inner wall surface of the first mounting hole 1233A, thereby improving the structural stability, and the third suspension 123 can be driven to a more accurate mounting position, thereby improving the mounting accuracy of the third suspension 123 and avoiding position interference between the third suspension 123 and other components.

[0144] In some embodiments, the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A in the up-down direction Z can be 0.5mm-1.5mm, for example, 0.5mm, 0.8mm, 1mm, 1.2mm, 1.5mm, etc., so as to avoid that the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A is too large, causing the mounting bolt 128 to be unable to match the installation, or the distance between the center position of the first mounting hole 1233A and the center position of the second mounting hole 127A is too small, which cannot improve the mounting accuracy of the third suspension 123.

[0145] Further, as shown in FIGS. 8 and 9, the diameter of the first mounting hole 1233A is greater than the diameter of the mounting bolt 128.

[0146] In this embodiment, the diameter of the first mounting hole 1233A is greater than the diameter of the mounting bolt 128, so that the mounting bolt 128 has a certain displacement in the up-down direction Z in the first mounting hole 1233A, so that after the subsequent range extender assembly 130 is assembled, the third suspension 123 can be pulled down by the weight of the range extender assembly 130 itself, so that the mounting bolt 128 is attached to the inner wall surface of the first mounting hole 1233A. In addition, the diameter of the first mounting hole 1233A is greater than the diameter of the mounting bolt 128, which facilitates the matching installation of the mounting bolt 128 and reduces the installation difficulty of the mounting bolt 128, thereby avoiding the improvement of the installation convenience.

[0147] Exemplarily, the diameter of the first mounting hole 1233A can be 13 mm, and the diameter of the mounting bolt 128 can be 12 mm, so as to facilitate the matching installation of the mounting bolt 128 and the first mounting hole 1233A. Of course, the diameters of the first mounting hole 1233A and the mounting bolt 128 can also be other values, which can be set according to actual needs, and are not limited herein.

[0148] In a specific embodiment, as shown in FIGS. 8 and 9, the elastic member 1232 includes a mounting portion 1232A and a connecting arm 1232B, one end of the connecting arm 1232B is connected with the inner wall of the bushing seat 1231, and the other end of the connecting arm 1232B is connected with the mounting portion 1232A; the mounting portion 1232A includes a mounting cavity, and the inner core 1233 is installed in the mounting cavity.

[0149] In this embodiment, the inner core 1233 is arranged in the mounting cavity of the mounting portion 1232A, which can improve the connection stability of the inner core 1233 and the elastic member 1232. After the range extender assembly 130 is assembled, the inner core 1233 is displaced by the vibration of the range extender assembly 130, and the connecting arm 1232B connected with the bushing seat 1231 and the mounting portion 1232A can provide a reverse pulling force and a buffering force for the inner core 1233, which can adaptively reduce the jitter of the range extender assembly 130 during the operation of the range extender assembly 130, and avoid the vibration amplitude of the inner core 1233 and the range extender assembly 130 being too large, thereby achieving a good buffering effect during the vibration of the range extender assembly 130.

[0150] Further, as shown in FIG. 10, which is a partial enlarged view of FIG. 9, the inner core 1233 includes a first arc surface 1233B, a second arc surface 1233C, and a connecting surface 1233D connected between the first arc surface 1233B and the second arc surface 1233C. The diameter of the first arc surface 1233B is greater than the diameter of the second arc surface 1233C, and the connecting arm 1232B is connected with the corresponding positions of the second arc surface 1233C and the connecting surface 1233D on the mounting portion 1232A.

[0151] In this embodiment, the diameter of the first arc surface 1233B is large, so that the inner core 1233 has sufficient volume to open the corresponding positioning hole and mounting hole, improves the overall strength of the inner core 1233, avoids damage to the inner core 1233 under stress, and improves the structural stability of the third suspension 123. In addition, the diameter of the second arc surface 1233C is relatively small compared to the first arc surface 1233B, and the corresponding positions of the second arc surface 1233C and the connecting surface 1233D on the connecting arm 1232B and the mounting portion 1232A are connected, which can improve the volume of the connecting arm 1232B, thereby improving the buffering effect of the connecting arm 1232B, and can improve the connecting area of the connecting arm 1232B and the corresponding inner core 1233 on the mounting portion 1232A, thereby avoiding the stress of the inner core 1233 on the connecting arm 1232B too concentrated, improving the fatigue durability of the connecting arm 1232B, and prolonging the service life of the elastic member 1232.

[0152] In this embodiment, the number of connecting arms 1232B can be 2, symmetrically arranged on opposite sides of the mounting portion 1232A and the inner core 1233, to avoid the stress of the inner core 1233 on the connecting arm 1232B too concentrated, improve the fatigue durability of the connecting arm 1232B. Of course, the number of connecting arms 1232B can also be 2, 3, 4, etc., to improve the design freedom, which can be set according to actual needs, which is not limited here.

[0153] In one specific embodiment, as shown in FIG. 9, the elastic member 1232 further comprises a first buffer portion 1232C and a second buffer portion 1232D, the first buffer portion 1232C and the connecting arm 1232B and the mounting portion 1232A form a first gap 1234, and the second buffer portion 1232D and the connecting arm 1232B and the mounting portion 1232A form a second gap 1235. The first gap 1234 and the second gap 1235 are arranged in the up-down direction Z.

[0154] In this embodiment, the first gap 1234 and the second gap 1235 can provide a moving buffer space for the inner core 1233 with the vibration of the range extender assembly 130, further reducing the force transmitted by the inner core 1233 to the first buffer portion 1232C and the second buffer portion 1232D, improving the buffering effect, reducing the influence of the vibration of the range extender assembly 130 on the range extender vehicle body, and improving the stability of the range extender vehicle body.

[0155] FIG. 11 shows a structural schematic view of the third suspension 123 at another angle. In one specific embodiment, as shown in FIG. 8, the third suspension 123 further comprises a second main plate 1236, one end of the second main plate 1236 is connected with the bushing seat 1231, and the other end of the second main plate 1236 is provided with a mounting surface 1236A, and the mounting surface 1236A is connected with the range extender assembly 130.

[0156] In this embodiment, as shown in FIGS. 8 and 11, the mounting surface 1236A on the second main plate 1236 is connected and fixed with the range extender assembly 130, which can increase the connection area of the third suspension 123 with the range extender assembly 130, thereby improving the connection strength of the third suspension 123 with the range extender assembly 130 and reducing the shaking between the range extender assembly 130 and the third suspension 123, and improving the structural stability of the vehicle.

[0157] In this embodiment, the mounting surface 1236A can be symmetrically arranged on the second main plate 1236 to improve the contact area of the mounting surface 1236A with the range extender assembly 130, thereby improving the connection strength. In other embodiments, the second main plate 1236 can be symmetrically arranged on the opposite sides of the bushing seat 1231 to improve the design freedom of the third suspension 123, so that the third suspension 123 can adapt to the range extender vehicle body structure of different vehicles.

[0158] In addition, the size of the third suspension 123 can be changed according to the size and position of the range extender assembly 130, which can be set according to actual needs, so that the third suspension 123 can adapt to the range extender vehicle body structure of different vehicles, which is not limited herein.

[0159] In a specific embodiment, as shown in FIG. 11, the thickness of the second main plate 1236 is 4mm-5mm. For example, the thickness of the second main plate 1236 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc., which can be set according to actual needs, which is not limited herein.

[0160] If the thickness of the second main plate 1236 is too thin, for example, less than 4mm, the static stiffness and dynamic stiffness of the second main plate 1236 are both low, which is easy to bend and twist, so that the supporting and fixing effect of the third suspension 123 on the range extender assembly 130 is reduced, and vibration noise is also easy to occur. If the thickness of the second main plate 1236 is too thin, resonance between the second main plate 1236 and the range extender assembly 130 is easy to occur, so that the second main plate 1236 is easy to crack or break, which reduces the service life and also affects the range extender vehicle body and the vehicle cabin, thereby reducing the comfort of driving and riding. If the thickness of the second main plate 1236 is too thick, for example, greater than 5mm, the static stiffness and dynamic stiffness are both too high, which is easy to reduce the isolation effect of high-frequency vibration on the range extender assembly 130. In addition, the thickness of the second main plate 1236 is too thick, which is easy to increase the volume of the second main plate 1236, which is easy to interfere with other components in the range extender vehicle body 100, and also increases the overall weight and manufacturing cost of the third suspension 123, which is not conducive to the lightweight design of the vehicle.

[0161] Therefore, when the thickness of the second main plate 1236 is 4mm-5mm, the thickness of the second main plate 1236 is moderate, the volume is small, and it is not easy to interfere with other components. And the second main plate 1236 has appropriate static stiffness and dynamic stiffness, which can ensure that the second main plate 1236 has good supporting and fixing effect on the range extender assembly 130, and is not easy to resonate with the range extender assembly 130, thereby reducing the impact on the range extender vehicle body and the vehicle cabin, and also reducing the risk of cracks or fractures of the second main plate 1236, prolonging the service life. In addition, the second main plate 1236 also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the third suspension 123, and improve the comfort of driving and riding.

[0162] FIG. 12 shows a structural schematic diagram of the first suspension and the second suspension. As shown in FIG. 12, in one specific embodiment, the first suspension 111 and the second suspension 112 each include a suspension body 116, a connecting plate 117, a first main plate 118, and a nut plate 119. One end of the suspension body 116 is connected with the front engine compartment assembly 110, and the other end is connected with the first main plate 118 through the connecting plate 117. The nut plate 119 is arranged on the first main plate 118 and connected with the range extender assembly 130 through bolts.

[0163] In this embodiment, the suspension body 116 of the first suspension 111 and the second suspension 112 is connected with the first main plate 118 through the connecting plate 117, which has a simple structure, stable connection, and is easy to manufacture and assemble, and has a low cost. The arrangement of the nut plate 119 can avoid deformation of the first main plate 118 when the first suspension 111 and the second suspension 112 are connected with the range extender assembly 130, thereby improving the structural stability of the first main plate 118. In addition, the arrangement of the nut plate 119 can also avoid the first main plate 118 being too thick, thereby increasing the manufacturing cost and reducing the vibration isolation effect, and improving the NVH performance of the vehicle.

[0164] Among them, the suspension body 116 can be connected with the connecting plate 117 through bolts or welding, and the connecting plate 117 can be connected with the first main plate 118 through welding to improve the connection stability between the suspension body 116, the connecting plate 117, and the first main plate 118. The nut plate 119 can be formed on the surface of the first main plate 118 through welding or one-piece forming, thereby improving the structural stability of the first suspension 111 and the second suspension 112.

[0165] In addition, the first main plate 118 of the first suspension 111 and the second suspension 112 can be designed differently, and the number and position of the nut plate 119 on the first main plate 118 can also be different. Specifically, the number and position of the nut plate 119 on the first main plate 118 can be set according to the installation requirements of the range extender assembly 130 with the first suspension 111 and the second suspension 112, which is not limited herein.

[0166] Fig. 13 shows a partial structural schematic diagram of the first suspension, and Fig. 14 shows a partial structural schematic diagram of the second suspension. As shown in Figs. 13 and 14, in one specific embodiment, the thickness of the first main plate 118 is 4mm-5mm, and / or the thickness of the nut plate 119 is 3.5mm-4.5mm, and / or the thickness of the connecting plate 117 is 4mm-5mm. For example, the thickness of the first main plate 118 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc., the thickness of the nut plate 119 can be 3.5mm, 3.7mm, 4mm, 4.2mm, 4.5mm, etc., the thickness of the connecting plate 117 can be 4mm, 4.2mm, 4.5mm, 4.7mm, 5mm, etc., which can be set according to actual needs, and is not limited herein.

[0167] If the thickness of the first main plate 118, the nut plate 119, and / or the connecting plate 117 is too thin, the static stiffness and dynamic stiffness are both low, and bending and torsion are prone to occur, which reduces the supporting and fixing effect of the first suspension 111 and the second suspension 112 on the range extender assembly 130, and also causes vibration and abnormal noise. If the thickness of the first main plate 118, the nut plate 119, and / or the connecting plate 117 is too thin, resonance with the range extender assembly 130 is also prone to occur, which reduces the risk of cracks or fractures of the parts, reduces the service life, and also affects the range extended vehicle body and the vehicle cabin, which reduces the comfort of driving and riding. If the thickness of the first main plate 118, the nut plate 119, and / or the connecting plate 117 is too thick, the static stiffness and dynamic stiffness are both too high, which reduces the isolation effect of high-frequency vibration on the range extender assembly 130. Moreover, too thick thickness also increases the volume of the parts, which is prone to interfere with other parts in the range extended vehicle body 100, and also increases the overall weight and manufacturing cost of the first suspension 111 and the second suspension 112, which is not conducive to the lightweight design of the vehicle.

[0168] Therefore, when the thickness of the first main plate 118 is 4mm-5mm, and / or the thickness of the nut plate 119 is 3.5mm-4.5mm, and / or the thickness of the connecting plate 117 is 4mm-5mm, the thickness of the first main plate 118, the nut plate 119 and / or the connecting plate 117 is moderate, the overall structure formed is small in size and is not easy to interfere with other components. Moreover, the first main plate 118, the nut plate 119 and / or the connecting plate 117 have appropriate static stiffness and dynamic stiffness, which can ensure that the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 has a good supporting and fixing effect on the range extender assembly 130, is not easy to resonate with the range extender assembly 130, reduces the impact on the range extended vehicle body and the vehicle cabin, and also reduces the risk of cracking or breaking, thereby prolonging the service life. In addition, the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 also has good vibration isolation effect, which can improve the shock absorption and noise reduction performance of the first suspension 111 and the second suspension 112, thereby improving the comfort of driving and riding.

[0169] In a specific embodiment, when the maximum speed N of the engine in the range extender assembly 130 is 6000RPM, the 2nd order natural frequency f2 of the engine can be calculated as f2=N / 60*2=200Hz, and the 4th order natural frequency f4 of the engine can be calculated as f4=N / 60*4=400Hz. According to the noise, vibration and harshness (NVH) performance requirements of the vehicle, it is usually required that the first order modal natural frequency F of the suspension bracket is greater than or equal to 500Hz. In the embodiment of the present application, the thickness of the first main plate 118 of the first suspension 111 is 4.5mm, the thickness of the three nut plates 119 is 4mm, the thickness of the connecting plate 117 is 4.5mm, and the first order modal natural frequency of the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 is 633Hz; the thickness of the first main plate 118 of the second suspension 112 is 4.5mm, the thickness of the three nut plates 119 is 4mm, the thickness of the connecting plate 117 is 4.5mm, and the first order modal natural frequency of the overall structure formed by the first main plate 118, the nut plate 119 and the connecting plate 117 is 572Hz; the thickness of the second main plate 1236 of the third suspension 123 is 4.5mm, and the first order modal natural frequency thereof is 594Hz. In the present application, the first suspension 111, the second suspension 112 and the third suspension 123 can all meet the NVH performance requirements of the vehicle, avoid resonance with the range extender assembly 130, improve the NVH performance of the vehicle, and reduce the risk of cracking or breaking failure of the first suspension 111, the second suspension 112 and the third suspension 123.

[0170] FIG. 15 shows the first suspension 111 and the second suspension 112; FIG. 16 shows the third suspension 123; and FIG. 17 shows the middle channel 122 structure shown in FIG. 8.

[0171] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 8, FIG. 15, FIG. 16 and FIG. 17, in the embodiment, the floor assembly 120 further comprises a first floor cross beam 124 extending along the left-right direction Y, and at least part of the first floor cross beam 124 is fixedly attached to the lower side 1220 of the middle channel 122, and the third suspension 123 is arranged on the first floor cross beam 124.

[0172] The first floor cross beam 124 extends along the left-right direction Y, and at least part of the first floor cross beam 124 is fixedly attached to the lower side 1220 of the middle channel 122, that is, at least part of the first floor cross beam 124 is attached to the floor body 121, and the first floor cross beam 124 can partially support the floor body 121. Since the floor body 121 is subjected to relatively large force, the first floor cross beam 124 supports the floor body 121, which can effectively share the force of the floor body 121, avoid the single-point force condition of the floor body 121, and improve the service life and use efficiency of the floor body 121.

[0173] The third suspension 123 is arranged on the first floor cross beam 124, and the third suspension 123 is connected with the range extender assembly 130, so that part of the gravity of the range extender assembly 130 is borne by the first floor cross beam 124. Compared with directly arranging the third suspension 123 on the floor body 121, arranging the third suspension 123 on the first floor cross beam 124 can greatly reduce the force of the floor body 121. Moreover, the first floor cross beam 124 can significantly increase the structural strength of the middle channel 122, and the third suspension 123 is directly connected with the first floor cross beam 124 instead of being connected with the middle channel 122, which can improve the installation stability of the range extender assembly 130. In addition, the first floor cross beam 124 can buffer the vibration generated by the range extender assembly 130, thereby improving the overall shock absorption performance of the vehicle, and further greatly improving the use comfort of the user. For example, the first floor cross beam 124 can increase the structural strength of the middle channel 122 by 20%, ensuring the structural stability of the floor body 121.

[0174] In some embodiments, the first floor cross beam 124 can be made of a material with high strength. For example, the first floor cross beam 124 can be made of steel or aluminum alloy. Steel has high strength and rigidity, which can provide stable support for the extended-range vehicle body. The high strength and rigidity ensure that the first floor cross beam 124 does not deform under various loads. In addition, steel is easy to shape and weld during processing, which ensures a firm connection between the first floor cross beam 124 and other components of the extended-range vehicle body 100. Steel also has good durability and fatigue resistance, which can maintain the stability of the first floor cross beam 124 during long-term use. Aluminum alloy has excellent lightweight performance and high rigidity. Compared with steel, using aluminum alloy for the first floor cross beam 124 can significantly reduce the weight of the extended-range vehicle body, thereby improving fuel economy and reducing environmental impact. In addition, aluminum alloy has good corrosion resistance and can maintain a long service life in harsh environments.

[0175] In some embodiments, the first floor cross beam 124 and the third suspension 123 can be connected by bolts. Bolt connection is a detachable connection method that can be easily separated by removing the bolts when maintenance, replacement, or adjustment of the equipment is needed, without damaging the connecting parts themselves. Moreover, the bolts are made of high-strength materials such as carbon steel, stainless steel, or alloy steel, which can withstand large tensile and shear forces. In addition, by selecting the appropriate bolt diameter, length, and thread type, the carrying capacity and durability of the bolts can be further enhanced, ensuring long-term stability of the connection. Bolt connection has high precision because the tightness and stability of the connection can be ensured by controlling the tightening torque and pre-tightening force of the bolts. This precision helps to reduce looseness and vibration, improving the efficiency and reliability of the equipment. Bolt connection usually does not require complex installation tools or equipment, and can be completed using basic tools such as wrenches and screwdrivers. At the same time, due to the detachability of the bolts, maintenance and repair of the equipment become easier and more convenient.

[0176] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 15, FIG. 16, and FIG. 17. In this embodiment, the floor assembly 120 further includes a first floor longitudinal beam 125 and a second floor longitudinal beam 126. The first floor longitudinal beam 125 and the second floor longitudinal beam 126 are both arranged on the floor body 121 and extend in the front-rear direction X. The two ends of the first floor cross beam 124 in the length direction are respectively connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126.

[0177] The first floor longitudinal beam 125 and the second floor longitudinal beam 126 are spaced apart in the left-right direction Y, and are arranged on the floor body 121 and extend in the front-rear direction X. The first floor longitudinal beam 125 and the second floor longitudinal beam 126 can support the floor body 121, reduce the single-point stress of the floor body 121, and reduce the risk of stress concentration of the floor body 121.

[0178] The first floor transverse beam 124 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 in the length direction (the left-right direction Y), and the first floor longitudinal beam 125 and the second floor longitudinal beam 126 can support the first floor transverse beam 124. In addition, the first floor transverse beam 124 can greatly improve the force transmission performance of the floor assembly 120, so that the vehicle can quickly transmit the force when impacted by the force in the left-right direction Y.

[0179] Of course, the first floor transverse beam 124 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 in the length direction (the left-right direction Y), which can further improve the structural strength of the floor assembly 120, thereby improving the installation stability of the range extender assembly 130.

[0180] Since the range extender assembly 130 is connected with the first floor transverse beam 124 through the third suspension 123, and the first floor transverse beam 124 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, when the range extender assembly 130 generates vibration during operation, the first floor transverse beam 124 can disperse the vibration generated by the range extender assembly 130 through the first floor longitudinal beam 125 and the second floor longitudinal beam 126, thereby reducing the influence of the vibration generated by the range extender assembly during operation on the vehicle and improving the user's use comfort.

[0181] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 15, FIG. 16 and FIG. 17. In this embodiment, the front engine compartment assembly 110 includes a subframe 113, the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 respectively, and the first suspension 111 and the second suspension 112 are arranged on the subframe 113.

[0182] The front engine compartment assembly 110 comprises a subframe 113 arranged at the front of the range-extender vehicle body, the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, the first suspension 111 and the second suspension 112 are arranged on the subframe 113, the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 in the length direction (left-right direction Y), and the first floor longitudinal beam 125 and the second floor longitudinal beam 126 can support the subframe 113. Since the range-extender assembly 130 is connected with the subframe 113 through the first suspension 111 and the second suspension 112, and the subframe 113 is connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, the range-extender assembly 130 can be indirectly connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 through the subframe 113, and the installation of the range-extender assembly 130 is more free.

[0183] When the range-extender assembly 130 operates to generate vibration, the subframe 113 can disperse the vibration generated by the range-extender assembly 130 through the first floor longitudinal beam 125 and the second floor longitudinal beam 126, reduce the influence of the vibration generated by the range-extender assembly 130 when operating on the vehicle, and improve the user's use comfort.

[0184] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 15, FIG. 16 and FIG. 17, in the embodiment, the front engine compartment assembly 110 further comprises a first front engine compartment longitudinal beam 114 and a second front engine compartment longitudinal beam 115, the first front engine compartment longitudinal beam 114 extends along the front-rear direction X, the second front engine compartment longitudinal beam 115 extends along the front-rear direction X, and the second front engine compartment longitudinal beam 115 is spaced apart from the first front engine compartment longitudinal beam 114 in the left-right direction Y, wherein the subframe 113 is further connected with the first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 respectively.

[0185] Therefore, the subframe 113 not only connects the first floor longitudinal beam 125 and the second floor longitudinal beam 126 together, but also connects the first front engine compartment longitudinal beam 114 and the second front engine compartment longitudinal beam 115 together, so that the connection between the front engine compartment assembly 110 and the floor assembly 120 is more stable, and the installation stability of the range-extender assembly 130 is improved.

[0186] The auxiliary frame 113 is connected with the first front engine bay longitudinal beam 114 and the second front engine bay longitudinal beam 115, and the first suspension 111 and the second suspension 112 are arranged on the auxiliary frame 113. The auxiliary frame 113 is connected with the first front engine bay longitudinal beam 114 and the second front engine bay longitudinal beam 115 in the length direction (the left-right direction Y), and the first front engine bay longitudinal beam 114 and the second front engine bay longitudinal beam 115 can support the auxiliary frame 113. Since the range-extender assembly 130 is connected with the auxiliary frame 113 through the first suspension 111 and the second suspension 112, and the auxiliary frame 113 is connected with the first front engine bay longitudinal beam 114 and the second front engine bay longitudinal beam 115, when the range-extender assembly 130 generates vibration during operation, the auxiliary frame 113 can disperse the vibration generated by the range-extender assembly 130 through the first front engine bay longitudinal beam 114 and the second front engine bay longitudinal beam 115, reduce the influence of the vibration generated by the range-extender assembly 130 during operation on the vehicle, and improve the use comfort of the user.

[0187] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 15, FIG. 16 and FIG. 17, in the embodiment, the first floor cross beam 124 includes a first body part 124A, a second body part 124B and a protruding part 124C connected between the first body part 124A and the second body part 124B, the protruding part 124C protrudes upward compared with the first body part 124A and the second body part 124B, wherein the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, and the first body part 124A and the second body part 124B are both fixedly attached to the floor body 121.

[0188] The first body part 124A and the second body part 124B are spaced apart in the left-right direction Y, and the first body part 124A and the second body part 124B are connected through the protruding part 124C. The protruding part 124C protrudes upward compared with the first body part 124A and the second body part 124B, and the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, that is, the protruding part 124C can support the lower side 1220 of the middle channel 122. The first body part 124A and the second body part 124B can be attached to the floor body 121, and the first body part 124A and the second body part 124B can support the floor body 121. The first body part 124A and the second body part 124B can be connected with the first floor longitudinal beam 125 and the second floor longitudinal beam 126 respectively.

[0189] Specifically, the protruding part 124C is fixedly attached to the lower side 1220 of the middle channel 122, and the first body part 124A and the second body part 124B are both fixedly attached to the floor body 121. This can reduce the single-point stress condition of the floor body 121, reduce the risk of stress concentration of the floor body 121, improve the service life of the floor body 121, and further improve the service life of the whole vehicle.

[0190] Fig. 18 shows a partial structural schematic diagram of the first floor cross beam 124 in an embodiment, in which the third suspension mounting bracket 127 is arranged on the protruding portion 124C, so that the third suspension 123 is arranged on the protruding portion 124C through the third suspension mounting bracket 127.

[0191] Fig. 19 shows a partial structural schematic diagram of the extended-range automobile body in an embodiment, and Fig. 20 shows an exploded schematic diagram of the partial structure of the first floor cross beam 124 in an embodiment.

[0192] As shown in Fig. 19 and Fig. 20, in an embodiment, the first body portion 124A and the second body portion 124B each include a first connecting portion 1241 and a second connecting portion 1242, and the first connecting portion 1241 is connected between the protruding portion 124C and the second connecting portion 1242.

[0193] The first connecting portion 1241 can be connected to the protruding portion 124C and the second connecting portion 1242 by means of screws or welding, so as to improve the connection strength and the structural stability of the first floor cross beam 124.

[0194] In the embodiment, the first body portion 124A and the second body portion 124B each include the first connecting portion 1241 and the second connecting portion 1242, so that the first connecting portion 1241, the second connecting portion 1242 and the protruding portion 124C can be manufactured respectively, facilitating the replacement of the first connecting portion 1241, the second connecting portion 1242 or the protruding portion 124C, improving the design freedom of the first floor cross beam 124, making the first floor cross beam 124 applicable to different vehicle models, and improving the use range of the first floor cross beam 124.

[0195] Specifically, when manufacturing the protruding portion 124C, an insert block can be arranged on the mold base of the preparation tool, and the insert block is a replaceable structure, so that the insert block can be added, subtracted or replaced according to actual needs, so as to adjust the structural size of the protruding portion 123C to adapt to different vehicle models. In this way, the mold cost can be reduced, thereby reducing the development cost. The first connecting portion 1241 and the second connecting portion 1242 of the first body portion 124A and the second body portion 124B can also be manufactured by arranging an insert block on the mold base of the preparation tool or by using different specifications and sizes of molds, so as to adjust the first connecting portion 1241 and the second connecting portion 1242 to adapt to different vehicle models and improve the design freedom.

[0196] In addition, the structural strength of the first connecting portion 1241, the second connecting portion 1242, and the protruding portion 124C can be set to be different, so that the first floor transverse beam 124 formed by assembly becomes a variable strength structure, so that the first floor transverse beam 124 can adjust the structural strength according to the stress condition at different positions, so as to reduce the overall weight of the first floor transverse beam 124 and save costs.

[0197] In some embodiments, the first connecting portion 1241, the second connecting portion 1242, and the protruding portion 124C can be formed by using different materials, different thicknesses, or different manufacturing processes, so that the structural strength of the first connecting portion 1241, the second connecting portion 1242, and the protruding portion 124C is different.

[0198] In a specific embodiment, as shown in FIG. 19, the strength of the material of the protruding portion 124C is higher than the strength of the material of the first connecting portion 1241 and the second connecting portion 1242, or the thickness of the protruding portion 124C is greater than the thickness of the first connecting portion 1241 and the second connecting portion 1242.

[0199] In this embodiment, the structural strength of the protruding portion 124C is higher than the structural strength of the first connecting portion 1241 and the second connecting portion 1242, so as to improve the supporting effect of the protruding portion 124C on the center channel 122, thereby ensuring the structural stability of the floor assembly 120. When the strength of the material of the protruding portion 124C is higher than the strength of the material of the first connecting portion 1241 and the second connecting portion 1242, the structural strength of the protruding portion 124C can be higher than that of the first connecting portion 1241 and the second connecting portion 1242, thereby improving the supporting effect of the protruding portion 124C on the center channel 122, and the thickness of the protruding portion 124C can be made thinner, thereby reducing the occupied space of the protruding portion 124C and improving the space utilization of the center channel 122. When the thickness of the protruding portion 124C is greater than the thickness of the first connecting portion 1241 and the second connecting portion 1242, the structural strength of the protruding portion 124C of the same material can be higher than that of the first connecting portion 1241 and the second connecting portion 1242, so as to ensure the supporting effect of the protruding portion 124C on the center channel 122.

[0200] The second connecting portion 1242 of the first body portion 124A away from the first connecting portion 1241 is connected with the first floor longitudinal beam 125, and the second connecting portion 1242 of the second body portion 124B away from the first connecting portion 1241 is connected with the second floor longitudinal beam 126, thereby improving the connection strength of the first floor transverse beam 124 with the first floor longitudinal beam 125 and the second floor longitudinal beam 126, and the connection stability of the first floor transverse beam 124 on the floor body 121, thereby ensuring the supporting effect of the first floor transverse beam 124 on the floor body 1.

[0201] In a specific embodiment, as shown in FIGS. 19 and 20, the first connecting portion 1241 includes oppositely bent first and second bent segments 1241A and 1241B, the first bent segment 1241A being connected with the protruding portion 124C, and the second bent segment 1241B being connected with the second connecting portion 1242.

[0202] In the embodiment, the first connecting portion 1241 includes oppositely bent first and second bent segments 1241A and 1241B, which can increase the connecting area of the first connecting portion 1241 with the protruding portion 124C and the second connecting portion 1242, and thus increase the connecting strength of the connecting portions of the components, so as to improve the structural stability of the first floor beam 124.

[0203] The manufacturing materials and processes of the first connecting portion 1241, the second connecting portion 1242, or the protruding portion 124C can be different, specifically, tubular materials can be used to form the first connecting portion 1241, the second connecting portion 1242, or the protruding portion 124C through an expansion process, or they can be formed through die casting, or they can be formed through other ways, so that the different components of the first floor beam 124 can be matched with the floor body 121 or the third suspension mounting bracket 127 in different ways, further improving the design freedom of the extended-range vehicle body, which can be set according to actual needs, and is not limited herein.

[0204] FIG. 21 shows a partial structure schematic diagram of the floor assembly 120 in a specific embodiment.

[0205] In a specific embodiment, as shown in FIGS. 19 and 20, the first floor beam 124 is symmetrically arranged in the left-right direction Y.

[0206] In the embodiment, as shown in FIGS. 19 to 21, the first floor beam 124 is symmetrically arranged in the left-right direction Y, which can realize the modularization of the first floor beam 124, so that the first floor beam 124 can move in the front-rear direction X in the middle channel 122 of the floor body 121, so that the first floor beam 124 can adapt to different vehicle models, improve the application range of the first floor beam 124, and reduce the development cost.

[0207] The first connecting portions 1241 of the first and second body portions 124A and 124B can be arranged the same, so as to realize the universality of the first connecting portions 1241 of the first and second body portions 124A and 124B, which can make the first connecting portions 1241 be manufactured uniformly, reduce the manufacturing molds, and further reduce the manufacturing cost.

[0208] In some other embodiments, the first connecting portion 1241, the second connecting portion 1242 and the protruding portion 124C of the first floor cross beam 124 can also be integrally formed so as to facilitate mass production of the first floor cross beam 124 and save manufacturing cost. Specifically, a tubular material can be integrally formed through an expansion process or can also be integrally formed through die casting, and of course can also be formed through other manners, which can be specifically set according to actual needs and is not limited herein.

[0209] In the related art, since the range-extender assembly in the range-extender vehicle integrates the generator, the electric motor and the generator controller, the range-extender assembly has a large volume and needs to occupy a large amount of front engine compartment space, resulting in that the space defined by the front engine compartment assembly must be large enough to meet the installation requirements of the range-extender.

[0210] In the embodiment, referring to FIGS. 2, 3, 4, 5, 6, 15, 16 and 17, the range-extender vehicle body 100 includes a front engine compartment assembly 110, a floor assembly 120 and a range-extender assembly 130. The front engine compartment assembly 110 defines a first accommodating space 110A. The floor assembly 120 is located behind the front engine compartment assembly 110 and includes a floor body 121 and a middle channel 122 arranged on the floor body 121. The middle channel 122 defines a second accommodating space 122A. The second accommodating space 122A communicates with the first accommodating space 110A. A part of the range-extender assembly 130 is arranged in the first accommodating space 110A, and another part of the range-extender assembly 130 is arranged in the second accommodating space 122A. Since a part of the range-extender assembly 130 is arranged in the first accommodating space 110A and another part of the range-extender assembly 130 is arranged in the second accommodating space 122A, the space below the front engine compartment assembly 110 and the floor assembly 120 of the range-extender vehicle body 100 can be fully utilized, and even a vehicle with a small front engine compartment can be designed as a range-extender vehicle.

[0211] The front engine compartment assembly 110 defines a first accommodating space 110A. The floor assembly 120 is located behind the front engine compartment assembly 110, that is, the floor assembly 120 is located behind the first accommodating space 110A. The floor assembly 120 includes a floor body 121 and a central channel 122 disposed in the floor body 121. Due to the complex structural limitations of the range-extended vehicle body 100 itself, the cross-sectional shape of the floor body 121 along the front-rear direction X can be approximately Z-shaped, thus forming a central channel 122 below the floor body 121. The central channel 122 defines a second accommodating space 122A. The first accommodating space 110A and the second accommodating space 122A are connected. The second accommodating space 122A is behind the first accommodating space 110A, and the first accommodating space 110A is in front of the second accommodating space 122A. A portion of the range extender assembly 130 is disposed in the first receiving space 110A, and another portion of the range extender assembly 130 is disposed in the second receiving space 122A, that is, the range extender assembly 130 spans the first receiving space 110A and the second receiving space 122A.

[0212] For vehicles with a smaller front engine compartment assembly 110, the smaller design means less drag as air flows through the area, improving the vehicle's aerodynamic performance. This design reduces wind resistance during driving, thus improving fuel economy and reducing energy loss. The smaller front engine compartment assembly 110 also reduces air turbulence, making the vehicle more stable at high speeds, contributing to higher top speeds and acceleration performance. Furthermore, the smaller front engine compartment assembly 110 means fewer materials and components are needed for construction, helping to reduce the vehicle's curb weight and effectively lowering overall manufacturing costs.

[0213] The front engine compartment assembly 110 is relatively small, and generally the first accommodating space 110A is also relatively small, and the volume of the range extender assembly 130 is relatively large. By arranging a part of the range extender assembly 130 in the first accommodating space 110A and arranging another part of the range extender assembly 130 in the second accommodating space 122A, the volume occupied by the range extender assembly 130 in the first accommodating space 110A can be significantly effectively reduced, and then the vehicle model with a smaller front engine compartment assembly 110 (a smaller first accommodating space 110A) can also install the larger range extender assembly 130, thereby expanding the range of vehicle models to which the range extender assembly 130 is applicable. For example, for a vehicle model with a larger front engine compartment assembly 110 and a larger first accommodating space 110A, by arranging a part of the range extender assembly 130 in the first accommodating space 110A and arranging another part of the range extender assembly 130 to extend into the second accommodating space 122A, the space occupancy of the front engine compartment assembly 110 can also be effectively saved, and then the remaining space in the front engine compartment assembly 110 can be used to arrange a storage space or other components, thereby significantly improving the space utilization of the vehicle interior, and further, the use space of the passengers can be expanded and the use comfort of the passengers can be improved. Moreover, by arranging the range extender assembly 130 in the first accommodating space 110A and the second accommodating space 122A, compared with arranging the range extender assembly 130 in the first accommodating space 110A or the second accommodating space 122A alone, the accommodating space in which the range extender assembly is arranged is larger, which is beneficial to dissipating the heat generated by the range extender assembly 130 during operation, and thereby the service life and working efficiency of the range extender assembly 130 can be improved.

[0214] For example, the structure can shorten the front overhang length of the range extender assembly 130 in the front engine compartment assembly 110 by more than 170 mm, that is, the passenger compartment space can be increased by more than 170 mm, thereby improving the space utilization of the vehicle body interior of the range extended vehicle.

[0215] In some embodiments, the range extended vehicle body further comprises a fuel tank 190, and the fuel tank 190 is arranged between the battery 170 and the electric motor 180.

[0216] Specifically, by arranging a part of the range extender assembly 130 in the first accommodating space 110A defined by the front engine compartment assembly 110 and arranging another part of the range extender assembly 130 in the second accommodating space 122A defined by the center tunnel 122, the vehicle model with a smaller front engine compartment assembly 110 (a smaller vehicle head) can also install the range extender assembly 130, thereby making the range extender assembly 130 applicable to multiple vehicle models and expanding the range of vehicle models to which the range extender assembly 130 is applicable, and improving the space utilization of the vehicle interior.

[0217] Please refer to FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6, FIG. 15, FIG. 16 and FIG. 17, in the embodiment, the range extender assembly 130 includes an engine 131 and a generator 132, the engine 131 is power connected with the generator 132, the engine 131 is located at the front side of the generator 132, part of the engine 131 is arranged in the first accommodating space 110A, and the other part of the engine 131 and the generator 132 are arranged in the second accommodating space 122A.

[0218] The engine 131 of the range extended vehicle is mainly used for power generation, rather than directly driving the vehicle, the range extender assembly 130 can include the engine 131 and the generator 132, the engine 131 and the generator 132 are power connected, the mechanical energy of the engine 131 crankshaft rotation is converted into electric energy by the generator 132, the generator 132 is internally provided with a magnetic field and a conductor coil, when the conductor coil rotates in the magnetic field, an electromotive force will be generated at both ends of the conductor coil, and then an electric current is generated, thereby supplying power to the battery 170, generally, when the battery 170 has sufficient power, the electric motor 180 directly utilizes the power of the battery 170 to drive the vehicle, when the battery 170 has insufficient power, the engine 131 and the generator 132 are cooperatively operated, the engine 131 starts and drives the generator 132 to generate power, the generator 132 charges the battery 170 or directly supplies power to the electric motor 180.

[0219] The battery 170 is arranged in the middle of the vehicle, the engine 131 is located at the front side of the generator 132, that is, along the front-rear direction X of the vehicle, the distance between the engine 131 and the battery 170 is farther, the distance between the generator 132 and the battery 170 is closer, the electric motor 180 is arranged at the rear of the battery 170, the distance between the generator 132 and the battery 170 is also closer relative to the engine 131, in this way, on the one hand, the circuit layout inside the vehicle can be simplified, and the probability of vehicle failure can be reduced, on the other hand, the position of the generator 132 is closer to the positions of the battery 170 and the electric motor 180, and the power transmission loss can be reduced, the power generation efficiency can be improved, and then the cruising range of the range extended vehicle can be improved.

[0220] Specifically, part of the engine 131 is arranged in the first accommodating space 110A, and the other part of the engine 131 and the generator 132 are arranged in the second accommodating space 122A, since the front engine assembly 110 defines the first accommodating space 110A, the second accommodating space 122A is arranged below the floor assembly 120, the engine 131 will generate relatively large noise and vibration when working, compared with arranging the engine 131 entirely in the second accommodating space 122A, arranging part of the engine 131 in the first accommodating space 110A can obviously greatly reduce the influence of the vibration and noise generated by the engine 131 on the passengers, and greatly improve the use comfort of the vehicle.

[0221] Please refer to FIG. 22 to FIG. 25, FIG. 22 is a structural schematic diagram of the range extender assembly 130 provided by an embodiment of the present application; FIG. 23 is a partial enlarged view of the range extender assembly 130 provided by an embodiment of the present application; FIG. 24 is a partial enlarged view of the range extender assembly 130 provided by an embodiment of the present application; and FIG. 25 shows the third suspension 123.

[0222] In the embodiment, the range extender assembly 130 further comprises a generator controller 133, the generator 132 comprises a first housing 140, the motor controller comprises a second housing 141, and the range extender assembly 130 further comprises a third housing 142, the third housing 142 and the first housing 140 jointly define a first space accommodating the stator and rotor, and the third housing 142 and the second housing 141 jointly define a second space accommodating electrical components.

[0223] The engine 131 is connected with the generator 132 and is arranged in front of the generator 132, the generator 132 is connected with the generator controller 133 and is arranged in front of the generator controller 133. The first housing 140, the second housing 141 and the third housing 142 are all arranged on the range extender assembly 130, the first housing 140 and the third housing 142 define the first space accommodating the stator and rotor (the generator 132), and the second housing 141 and the third housing 142 jointly define the second space accommodating electrical components.

[0224] Specifically, the first housing 140, the second housing 141 and the third housing 142 jointly define an accommodation space accommodating the generator 132 and the generator controller 133, the generator 132 and the generator controller 133 share the third housing 142, which can greatly reduce the manufacturing cost of the generator 132 and the generator controller 133 and improve the assembly efficiency of the generator 132 and the generator controller 133.

[0225] Please refer to FIG. 22 to FIG. 25, in the embodiment, the upper side of the first housing 140 is provided with a recessed portion 140A recessed upward, and the first housing 140 is further provided with a plurality of reinforcing ribs 160, each reinforcing rib 160 is connected to the inner wall surface of the recessed portion 140A and extends along the front-rear direction X.

[0226] The upper side of the first housing 140 is provided with a recessed portion 140A recessed upward, and the first housing 140 is further provided with a plurality of reinforcing ribs 160, each reinforcing rib 160 is connected to the inner wall surface of the recessed portion 140A and extends along the front-rear direction X.

[0227] In some embodiments, four mounting holes 200 can also be provided on the third housing 142, and the third suspension 123 is fixedly connected with the four mounting holes 200, so that the range-extender assembly 130 can be hung on the third suspension 123.

[0228] Please refer to FIGS. 22-25. In this embodiment, the range-extender assembly includes an engine 131 and a generator 132, the engine 131 is power-connected with the generator 132, the engine 131 is located at the front side of the generator 132, the engine 131 has a first power output shaft 131A, the generator 132 has a first power input shaft 132A, the first power output shaft 131A is parallel with the second power input shaft and both extend in the front-rear direction X.

[0229] The engine 131 is power-connected with the generator 132, the engine 131 is located at the front side of the generator 132, the first power output shaft 131A of the engine 131 is connected with the first power input shaft 132A of the motor 180, the first power output shaft 131A of the engine 131 rotates to drive the first power input shaft 132A of the generator 132 to rotate.

[0230] That is, the engine 131 and the generator 132 are both installed in the front-rear direction X, thereby reducing the space occupation in the left-right direction Y of the front engine assembly 110.

[0231] The first power output shaft 131A can be arranged above the first power input shaft 132A, the first power output shaft 131A and the first power input shaft 132A are parallel and extend in the front-rear direction X, which can make the power of the engine 131 more smoothly transmitted to the generator 132, improve the overall modal of the vehicle system, and reduce the vibration of the range-extender assembly 130.

[0232] Please refer to FIGS. 22-25. In this embodiment, the range-extender vehicle body further includes a speed increaser 150, the speed increaser 150 includes a first driving gear 151 and a first driven gear 152 which are engaged with each other, the first driving gear 151 is power-connected with the engine 131, the first driven gear 152 is power-connected with the generator 132, wherein the rotation axis of the first driving gear 151 and the rotation axis of the second driving gear are spaced apart in the up-down direction Z.

[0233] The first driving gear 151 of the speed increaser 150 is power-connected with the engine 131, the first driven gear 152 of the speed increaser 150 is power-connected with the generator 132, that is, the power output by the engine 131 is transmitted to the first driving gear 151 of the speed increaser 150, the first driving gear 151 transmits power to the first driven gear 152, and then the first driven gear 152 transmits power to the generator 132. For example, the number of teeth of the first driving gear 151 is generally less than the number of teeth of the driven gear.

[0234] The rotation axis of the first driving gear 151 is spaced apart from the rotation axis of the first driven gear 152 in the up-down direction Z, so that the space of the front cabin assembly 110 in the up-down direction Z can be fully utilized, the space occupation of the speed increaser 150 in the left-right direction Y of the front cabin assembly 110 is reduced, and the range of application of the range extender assembly 130 can be expanded.

[0235] As shown in FIG. 26, the application also provides a manufacturing method of a range-extending automobile body, which is used for manufacturing the range-extending automobile body 100 in any of the above embodiments. The manufacturing method of the range-extending automobile body 100 comprises the following steps:

[0236] Step S1, manufacturing the front cabin assembly 110.

[0237] In this step, the front cabin assembly 110 disclosed in the embodiments of the application can comprise a first accommodating space, a first suspension, a second suspension, a subframe, a first front cabin longitudinal beam, and a second front cabin longitudinal beam.

[0238] Step S2, manufacturing the floor assembly 120. As shown in FIG. 21, the floor assembly 120 is provided with a middle channel 122.

[0239] In this step, the floor assembly 120 disclosed in the embodiments of the application can further comprise a floor body, a second accommodating space, a third suspension, a first floor cross beam, a first floor longitudinal beam, and a second floor longitudinal beam.

[0240] Step S3, connecting the floor assembly 120 and the front cabin assembly 110, as shown in FIGS. 2-5.

[0241] In this step, the floor assembly 120 and the front cabin assembly 110 are connected to form a whole, so that the range extender assembly 130 is connected to the floor assembly 120 and the front cabin assembly 110 through the first suspension 111, the second suspension 112, and the third suspension 123.

[0242] Step S4, connecting the first suspension 111, the second suspension 112, and the third suspension 123 to the range extender assembly 130, as shown in FIGS. 2, 7, and 8. The first suspension 111 and the second suspension 112 are spaced apart in the left-right direction Y, and the third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z.

[0243] In this step, the first suspension 111, the second suspension 112 and the third suspension 123 are connected with the range extender assembly 130 to form an integral whole, so that the range extender assembly 130 is connected with the integral structure formed by the first suspension 111, the second suspension 112 and the third suspension 123, the floor assembly 120 and the front engine compartment assembly 110.

[0244] In step S5, the first suspension 111 and the second suspension 112 are connected with the front engine compartment assembly 110, and the third suspension 123 is connected with the middle channel 122, as shown in FIGS. 2, 3, 5, 6, 16 and 17.

[0245] In this step, the range extender assembly 130 is connected with the integral structure formed by the first suspension 111, the second suspension 112 and the third suspension 123, the floor assembly 120 and the front engine compartment assembly 110, so that the range extender assembly 130 is installed on the floor assembly 120 and the front engine compartment assembly 110.

[0246] In this embodiment, the first suspension 111 and the second suspension 112 are arranged on the front engine compartment assembly 110, and the third suspension 123 is arranged on the middle channel 122. The first suspension 111 and the second suspension 112 are arranged in the first accommodating space 110A, and the third suspension 123 is arranged in the second accommodating space 122A. The first suspension 111 and the second suspension 112 are arranged in front of the third suspension 123, and the third suspension 123 is arranged behind the first suspension 111 and the second suspension 112. The first suspension 111 and the second suspension 112 are spaced apart in the front-rear direction X. The first suspension 111, the second suspension 112 and the third suspension 123 jointly form a triangular structure, and the range extender assembly 130 is fixed on the front engine compartment assembly 110 and the floor assembly 120 through the first suspension 111, the second suspension 112 and the third suspension 123.

[0247] Since the first suspension 111, the second suspension 112 and the third suspension 123 jointly form a triangular structure to fix the range extender assembly 130, on the one hand, the design of the triangular suspension can make the three suspension points be arranged more uniformly around the range extender assembly 130, forming a stable triangular support structure, which can effectively resist the torsion and vibration of the range extender assembly 130 from various sources during the driving of the vehicle, thereby maintaining the stability and reliability of the operation of the range extender assembly 130, improving the safety and reliability of the vehicle, and on the other hand, the triangular suspension can also attenuate the vibration generated by the range extender assembly 130 during operation, reduce the influence of the vibration generated by the range extender assembly 130 on other components of the range-extended vehicle body 100, improve the noise of the range-extended vehicle body, and improve the use comfort of the vehicle. For example, the noise of the range-extended vehicle body can be reduced by 3 decibels, and the use comfort of the vehicle can be improved.

[0248] The range extender assembly 130 is fixed on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension, and the independent installation and disassembly of the range extender assembly 130 can be realized, which is convenient for the maintenance and replacement of the range extender assembly 130 when the range extender assembly 130 fails, and thus the manufacturing and assembly efficiency of the whole vehicle can be improved. Moreover, the layout of the triangular suspension is relatively compact, the space inside the range extended vehicle body 100 can be maximally utilized, the interference with other components is reduced, and the space utilization of the whole vehicle is improved.

[0249] The range extender assembly 130 is fixed on the front engine compartment assembly 110 and the floor assembly 120 through the triangular suspension, which is also beneficial to reducing the loss of power during transmission, improving the power output efficiency of the range extender assembly 130, and further improving the overall performance of the vehicle.

[0250] The third suspension 123 is spaced apart from the first suspension 111 and the second suspension 112 in the up-down direction Z, that is, the first suspension 111 and the second suspension 112 can be below the third suspension 123, and the third suspension 123 is above the first suspension 111 and the second suspension 112, that is, the first suspension 111 and the second suspension 112 are arranged below the range extender assembly 130, and the third suspension 123 is arranged above the range extender assembly 130, which improves the stability and maneuverability of the vehicle, and the mass center distribution of the range extender assembly 130 is more reasonable. Moreover, the suspensions at different positions can be optimally arranged for vibrations in different directions, the first suspension 111 and the second suspension 112 arranged below the range extender assembly 130 are beneficial to the horizontal and vertical vibrations of the range extender assembly 130, and the third suspension 123 arranged above the range extender assembly 130 is beneficial to suppressing the longitudinal vibration of the range extender assembly 130. Such a layout is beneficial to comprehensively improving the vibration isolation effect, reducing the influence of vibration on the range extended vehicle body and the cab, reducing the probability of vehicle failure, and improving the stability of vehicle operation. For example, the probability of vehicle failure can be reduced by 20%, the stability of vehicle operation is improved, and the use cost of the user is reduced.

[0251] In addition, the range extender assembly 130 in the embodiment of the present application can be finally integrated and installed on the front engine compartment assembly 110 and the floor assembly 120 after being assembled with the first suspension 111, the second suspension 112 and the third suspension 123, so that the relative positions of the three mounting points in the free state meet the position accuracy requirements, the position tolerance in the assembly process can be reduced, and the position accuracy of the range extender assembly 130 is ensured. For example, the position tolerance can be reduced to within 2 mm to ensure the position accuracy of the range extender assembly.

[0252] In a specific embodiment, as shown in FIG. 27, the step S2 of manufacturing the floor assembly 120 specifically includes:

[0253] Step S21, manufacturing a floor blank 500.

[0254] In this step, the floor blank 500 can be a flat plate structure or an approximate flat plate structure with a certain thickness.

[0255] Step S22, as shown in FIG. 28, the floor blank 500 is subjected to drawing forming processing to form the floor body 121 and the middle channel 122, and to form the storage bump 501 on the middle channel 122.

[0256] In this step, the floor blank 500 can be placed between the drawing concave die 301 and the drawing convex die 302, and the floor blank 500 is subjected to pressure by the drawing concave die 301 and the drawing convex die 302, so that the floor blank 500 is drawn to form the floor body 121 and the middle channel 122, and to form the storage bump 501 on the middle channel 122.

[0257] Step S23, the floor blank 500 is subjected to shaping processing to press down the storage bump 501 to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121.

[0258] In this step, the floor blank 500 after drawing forming processing is placed between the shaping concave die 401 and the shaping convex die 402, and the floor blank 500 is subjected to pressure by the shaping concave die 401 and the shaping convex die 402, so that the storage bump 501 is pressed down to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121, thereby forming the floor assembly 120.

[0259] The middle channel 122 of the floor assembly 120 is deep in order to accommodate part of the range extender assembly 130, so that in the process of manufacturing the floor assembly 120, the drawing depth is too deep and the draft angle is too steep when the floor blank is drawn, which is easy to cause cracking on the middle channel 122, and the preparation yield is low.

[0260] In this embodiment, as shown in FIGS. 28 and 29, the floor blank 500 is subjected to drawing forming processing to form the floor body 121 and the middle channel 122, and to form the storage bump 501 on the middle channel 122. When the floor blank 500 after drawing forming processing is subjected to shaping, the storage bump 501 can be pressed down to form the arc-shaped corner 129 at the connection between the middle channel 122 and the floor body 121, thereby forming the floor assembly 120 to meet the use requirements of the range extended automobile body 100.

[0261] The manufacturing process is simple and facilitates mass production of the floor assembly 120. By forming the storage bump 501 on the middle channel 122 during the drawing forming process of the floor blank 500, a stepped structure is formed on the sidewall of the middle channel 122, thereby ensuring the overall depth of the middle channel 122 while avoiding a steep draft angle, improving the forming conditions, reducing the risk of cracking in the middle channel 122 during the drawing forming process, improving the production yield, and saving manufacturing costs. For example, the production yield of the middle channel 122 can be improved to 100%, avoiding cracking in the middle channel 122 during the drawing forming process.

[0262] As shown in FIG. 28, the drawing punch 302 and the drawing recess 301 can be provided with corresponding protrusions and recesses at positions corresponding to the storage bump 501, so that the storage bump 501 can be formed on the middle channel 122 during the drawing process.

[0263] In addition, as shown in FIG. 29, the storage bump 501 can be pressed down and formed into the arc corner 129 at the connection between the middle channel 122 and the floor body 121 by the shaping recess 401 and the shaping punch 402 that meet the use requirements of the extended-range vehicle body 100. The bump structure for shaping the storage bump 501 in the shaping recess 401 and the shaping punch 402 can be a block structure that can be detachably installed on the shaping recess 401 and the shaping punch 402, so as to shape the storage bump 501 of different sizes and further save manufacturing costs. In addition, a guide plate can be provided on the shaping block structure to ensure that the movement trajectory of the shaping block does not deviate and ensure the shaping effect.

[0264] Between step S22 and step S23, the manufacturing of the floor assembly 120 can also include steps such as trimming, punching, fine trimming, flanging, etc., which can be set according to actual needs and are not limited herein.

[0265] In a specific embodiment, as shown in FIGS. 28 and 29, the arc length of the storage bump 501 is equal to or approximately equal to the arc length of the corresponding arc corner 129. If the arc length of the storage bump 501 is too long, wrinkles and material folding are likely to occur at the arc corner 129 when the storage bump 501 is pressed down and formed into the arc corner 129 at the connection between the middle channel 122 and the floor body 121. If the arc length of the storage bump 501 is too short, the thickness of the formed arc corner 129 is likely to be too thin, reducing the structural strength, or the arc corner 129 is likely to crack.

[0266] Therefore, when the arc length of the storage protrusion 501 is equal to or approximately equal to the arc length of the corresponding arc corner 129, the overall thickness of the floor assembly 120 can be made uniform when the storage protrusion 501 is pressed down and shaped into the arc corner 129 at the connection between the intermediate channel 122 and the floor body 121. This avoids the risk of wrinkling, stacking, or cracking at the arc corner 129, further improving the manufacturing yield and saving manufacturing costs.

[0267] Preferably, the arc length of the material storage protrusion 501 is equal to the arc length of the corresponding arc corner 129, so as to ensure that the overall thickness of the formed floor assembly is uniform and to avoid wrinkling, stacking or cracking at the arc corner 129.

[0268] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0269] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on describing the differences from other embodiments. In particular, the system embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments.

[0270] The above description is merely an embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of this application should be included within the scope of the claims of this application.

[0271] Although embodiments of this application have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of this application, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

A range extended vehicle body, characterized by, The application relates to a front cabin assembly, a floor assembly and a range extender assembly. The front cabin assembly is provided with a first suspension and a second suspension which are spaced apart in the left-right direction. The floor assembly is located behind the front cabin assembly and comprises a floor body and a middle channel provided on the floor body; the middle channel is provided with a third suspension which is spaced apart from the first suspension and the second suspension in the front-rear direction and is also spaced apart from the first suspension and the second suspension in the up-down direction. The range extender assembly is fixed to the front cabin assembly and the floor assembly through the first suspension, the second suspension and the third suspension. The range extended vehicle body according to claim 1, wherein The third suspension comprises a bushing seat, an elastic member and an inner core; the elastic member is installed in the bushing seat, and the inner core is installed in the elastic member; the inner core is provided with a first mounting hole. The middle channel is provided with a third suspension mounting bracket which is provided with a second mounting hole; the second mounting hole is connected with the first mounting hole through a mounting bolt. The range extended vehicle body according to claim 2, wherein The diameter of the first mounting hole is larger than the diameter of the mounting bolt; and / or The center position of the first mounting hole is lower than the center position of the second mounting hole in the up-down direction. The range extended vehicle body according to claim 2, wherein The elastic member comprises a mounting part and a connecting arm; one end of the connecting arm is connected with the inner wall of the bushing seat, and the other end of the connecting arm is connected with the mounting part; the mounting part comprises a mounting cavity, and the inner core is installed in the mounting cavity. The range extended vehicle body according to claim 4, wherein The inner core comprises a first arc surface, a second arc surface and a connecting surface connected between the first arc surface and the second arc surface; the diameter of the first arc surface is larger than the diameter of the second arc surface. The connecting arm is connected with the corresponding positions of the second arc surface and the connecting surface on the mounting part. The range extended vehicle body according to claim 4, wherein The elastic member further comprises a first buffer part and a second buffer part. The first buffer part forms a first gap between the connecting arm and the mounting part; the second buffer part forms a second gap between the connecting arm and the mounting part. The first gap and the second gap are spaced apart in the up-down direction. The range extended vehicle body according to claim 2, wherein The third suspension further comprises a second main plate; one end of the second main plate is connected with the bushing seat, and the other end of the second main plate is provided with a mounting surface which is connected with the range extender assembly. The range extended vehicle body according to claim 7, wherein The thickness of the second main plate is 4mm-5mm. The range extended vehicle body according to any one of claims 1 to 8, characterized in that The first suspension and the second suspension each comprise a suspension body, a connecting plate, a first main plate and a nut plate. One end of the suspension body is connected with the front cabin assembly, and the other end of the suspension body is connected with the first main plate through the connecting plate. The nut plate is provided on the first main plate and is connected with the range extender assembly through a bolt. The range extended vehicle body according to claim 9, wherein The thickness of the first main plate is 4mm-5mm; and / or The thickness of the nut plate is 3.5mm-4.5mm; and / or The thickness of the connecting plate is 4mm-5mm. The range extended vehicle body according to any one of claims 1 to 8, characterized in that The floor assembly further comprises a first floor crossbeam extending in the left-right direction, and at least a portion of the first floor crossbeam is fixedly attached to the lower side of the middle channel, and the third suspension is arranged on the first floor crossbeam. The range extended vehicle body according to claim 11, wherein The first floor crossbeam comprises a first body portion, a second body portion, and a protruding portion connected between the first body portion and the second body portion, and the protruding portion protrudes upward compared with the first body portion and the second body portion; The protruding portion is fixedly attached to the lower side of the middle channel, and the first body portion and the second body portion are fixedly attached to the floor body; and the third suspension is arranged on the protruding portion. The range extended vehicle body according to claim 12, wherein The first body portion and the second body portion each comprise a first connecting portion and a second connecting portion, and the first connecting portion is connected between the protruding portion and the second connecting portion. The range extended vehicle body according to claim 13, wherein The material strength of the protruding portion is higher than the material strength of the first connecting portion and the second connecting portion. Alternatively, the thickness of the protruding portion is greater than the thickness of the first connecting portion and the second connecting portion. The range extended vehicle body according to claim 11, wherein The first floor crossbeam is symmetrically arranged in the left-right direction. The vehicle body according to any one of claims 1 to 8, characterized in that The front engine compartment assembly defines a first accommodating space, and the middle channel defines a second accommodating space, and the second accommodating space communicates with the first accommodating space. The range extender assembly comprises an engine and a generator, the engine is power-connected with the generator, and the engine is located at the front side of the generator. Part of the engine is arranged in the first accommodating space, and the other part of the engine and the generator are arranged in the second accommodating space. The range extended vehicle body according to claim 16, wherein The range extender assembly further comprises a generator controller, and the generator comprises a first shell, and the motor controller comprises a second shell. The range extender assembly further comprises a third shell, and the third shell and the first shell jointly define a first space for accommodating a rotor, and the third shell and the second shell jointly define a second space for accommodating electrical components. The upper side of the first shell is provided with a recessed portion recessed upward; The first shell is further provided with a plurality of reinforcing ribs, and each reinforcing rib is connected to the inner wall surface of the recessed portion and extends in the front-rear direction. A manufacturing method of a range extended vehicle body, characterized by, A manufacturing method of a vehicle body as claimed in any one of claims 1 to 17, the manufacturing method comprising: manufacturing a front engine compartment assembly; manufacturing a floor assembly provided with a middle channel; connecting the floor assembly with the front engine compartment assembly; connecting a first suspension, a second suspension, and a third suspension with a range extender assembly; wherein the first suspension and the second suspension are spaced apart in the left-right direction, and the third suspension is spaced apart from the first suspension and the second suspension in the up-down direction; connecting the first suspension and the second suspension with the front engine compartment assembly, and connecting the third suspension with the middle channel. The method of manufacturing an extended-range automotive vehicle body according to claim 18, wherein The manufacturing of the floor assembly specifically comprises: manufacturing a floor blank; performing a drawing forming process on the floor blank to form the floor body and the middle channel, and forming a storage protrusion on the middle channel; The floor blank is shaped to lower the storage convex to form an arc-shaped corner of the connection between the middle channel and the floor body. The method of manufacturing an extended-range automotive vehicle body according to claim 19, characterized by The arc length of the storage convex is equal to the arc length of the corresponding arc-shaped corner.

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