CN117458785A

CN117458785A - Range extender

Info

Publication number: CN117458785A
Application number: CN202311426436.2A
Authority: CN
Inventors: 郝自强; 凌新亮
Original assignee: Jing Jin Electric Technologies Beijing Co Ltd
Current assignee: Jing Jin Electric Technologies Beijing Co Ltd
Priority date: 2023-10-31
Filing date: 2023-10-31
Publication date: 2024-01-26

Abstract

The invention provides a range extender, comprising: the engine crankshaft is provided with a first flange surface at one end, and the first flange surface is provided with a first connecting hole; the rotor assembly is provided with a second flange surface at one end, and the second flange surface is provided with a second connecting hole; and the fastener is used for connecting the first connecting hole with the second connecting hole so as to fix the engine crankshaft and the rotor assembly together. According to the range extender provided by the invention, the first flange surface is arranged on the engine crankshaft, the second flange surface is arranged on the rotor assembly, and the engine crankshaft and the rotor assembly of the generator can be directly and rigidly connected through the fastener, so that components such as a coupler, a torsional damper, a flywheel, an engine adapter plate, a generator front end cover and the like can be reduced, the mechanism of the range extender is more compact, the size is small, the weight is light, the cost is reduced, and the reduction of the components of the range extender can also improve the overall reliability of the range extender.

Description

Range extender

Technical Field

The invention relates to the technical field of range extenders, in particular to a range extender.

Background

Along with the development of the automobile industry, energy conservation and environmental protection become the main direction of vehicle development, and extended range electric vehicles also should be generated. As the name suggests, the electric automobile is additionally provided with a range extender which can be used for generating electricity. The range-extending electric automobile has low requirement on the battery capacity, only the battery electric automobile is needed, the capacity is 30% -70%, the manufacturing cost can be greatly reduced, and the large-scale perfect charging facilities and the charging time are not needed. The range-extended electric vehicle has the advantages of energy conservation and emission reduction of a pure electric vehicle and long mileage of a pure internal combustion vehicle, and is a new energy vehicle with sustainable development.

The core of the range-extending electric vehicle is a range extender. Range extender refers to a combination of an engine and a generator. The existing range extender engine is provided with a flywheel, and a rotor shaft of the generator is connected with the flywheel of the engine through a torque damper.

In carrying out the invention, the inventors have found that at least the following problems exist in the prior art: the current connection mode between the engine and the generator of the range extender is that the spline coupling, the torsional damper, the flywheel, the engine adapter plate, the front end cover of the generator and the like are needed, and the generator is needed to be an independent whole. The main disadvantage of this kind of scheme is that spare part is more, and the structure is more complicated, and volume weight is all great, and the cost is high.

Disclosure of Invention

The present invention aims to solve at least one of the technical problems in the related art to a certain extent.

Therefore, the invention aims to provide the range extender which is compact in structure, small in size and light in weight.

In order to achieve the above object, the present invention provides a range extender, comprising:

the engine crankshaft is provided with a first flange surface at one end, and the first flange surface is provided with a first connecting hole;

the rotor assembly is provided with a second flange surface at one end, and the second flange surface is provided with a second connecting hole;

and the fastener is used for connecting the second connecting hole with the first connecting hole, so that the engine crankshaft and the rotor assembly are fixed together.

According to the range extender provided by the invention, the first flange surface is arranged on the engine crankshaft, the second flange surface is arranged on the rotor assembly, and the engine crankshaft and the rotor assembly of the generator can be directly and rigidly connected through the fastener, so that components such as a coupler, a torsional damper, a flywheel, an engine adapter plate, a generator front end cover and the like can be reduced, the mechanism of the range extender is more compact, the size is small, the weight is light, the cost is reduced, and the reduction of the components of the range extender can also improve the overall reliability of the range extender.

According to one embodiment of the invention, the engine crankshaft comprises a free end, a main journal and an output end integrally connected, the first flange face being provided on the output end.

According to one embodiment of the invention, the output end is provided laterally with an annular groove for positioning the engine crankshaft with an engine block forming a spigot.

According to one embodiment of the invention, the rotor assembly includes a rotor support and a rotor core secured to a sidewall of the rotor support.

According to one embodiment of the invention, the rotor support comprises a shaft body and an outer ring body, the second flange surface is arranged on the end face of the outer ring body, and the rotor core is fixed on the side wall of the outer ring body.

According to one embodiment of the invention, the outer ring body is provided with a plurality of through holes surrounding the shaft body.

According to one embodiment of the invention, the shaft body has a stepped shaft at an end remote from the output end.

According to one embodiment of the invention, the center of the shaft body has a hollowed hole with a stepped hole coaxial with the stepped shaft.

According to one embodiment of the invention, the stepped shaft comprises a first diameter section, a second diameter section and a third diameter section of progressively decreasing diameter.

According to one embodiment of the invention, further comprising a resolver, an auxiliary bearing and an oil pump, the resolver being mounted on the first diameter section for measuring the position and rotational speed of the rotor assembly; the auxiliary bearing is arranged on the second diameter section and is used for supporting the generator shell; the oil pump is arranged on the third diameter section and is used for providing cooling lubricating oil for the generator.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to designate like parts throughout the figures. Wherein:

fig. 1 is a side view of a range extender with the engine block and generator housing omitted in accordance with an embodiment of the present invention.

Fig. 2 is a cross-sectional view taken along line A-A of fig. 1.

Fig. 3 is an enlarged partial schematic view at a in fig. 2.

Fig. 4 is a side view of a range extender with an engine block omitted in accordance with an embodiment of the present invention.

Fig. 5 is a sectional view taken along line B-B of fig. 4.

Fig. 6 is a side view of a range extender in accordance with an embodiment of the present invention.

Fig. 7 is a sectional view taken along line C-C of fig. 7.

Reference numerals illustrate:

the engine comprises a 1-engine crankshaft, a 2-rotor assembly, a 3-rotary transformer, a 4-auxiliary bearing, a 5-oil pump, a 6-engine cylinder, a 7-generator housing, an 8-stator assembly, an 11-main journal, a 12-free end, a 13-output end, a 14-annular groove, a 15-blind hole, a 21-rotor bracket, a 22-rotor core, a 23-fastener, a 24-first diameter section, a 25-second diameter section, a 26-third diameter section, a 27-through hole, a 28-hollowed hole, a 211-shaft body and a 212-outer ring body.

Detailed Description

Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention. On the contrary, the embodiments of the invention include all alternatives, modifications and equivalents as may be included within the spirit and scope of the appended claims.

Referring to fig. 1 to 7, an embodiment of the present invention provides a range extender. The range extender comprises an engine crankshaft 1, a rotor assembly 2 and a fastener 23. The engine and the generator in the range extender are directly connected with each other through the engine crankshaft, and are directly and mechanically integrated, so that components such as a flywheel, a coupling, a torsional damper and the like in the prior art are omitted. In a serial system, the system reliability is equal to the reliability multiplication of the components, and therefore, the reduction of components helps to improve the reliability.

In particular, one end of the engine crankshaft 1 has a first flange surface with a first connecting hole. One end of the rotor assembly 2 has a second flange face with a second connection hole. The fastener 23 is used for connecting the second connecting hole with the first connecting hole in a threaded manner, so that the engine crankshaft 1 and the rotor assembly 2 are fixed together, and the engine crankshaft connecting device is convenient to assemble and simple in structure. The first connecting holes and the second connecting holes are arranged around the axis of the rotor assembly 2, the number of the first connecting holes and the number of the second connecting holes are consistent, and the specific number can be designed according to actual needs. The first connecting hole can be a screw hole, the second connecting hole is a through hole, and the fastener 23 passes through the second connecting hole and is in threaded connection with the first connecting hole. Alternatively, the first connecting hole may be a through hole, the second connecting hole may be a screw hole, and the fastener 23 may be threaded through the first connecting hole. Optionally, the number of the first connecting holes and the second connecting holes is 4 to 10, and the fastening effect is good.

According to the range extender provided by the embodiment of the invention, the first flange surface is arranged on the engine crankshaft, the second flange surface is arranged on the rotor assembly, and the engine crankshaft and the rotor assembly of the generator can be directly and rigidly connected through the fastener, so that components such as a coupler, a torsional damper, a flywheel, an engine adapter plate, a front end cover of the generator and the like can be reduced, the mechanism of the range extender is more compact, the size is small, the weight is light, the cost is reduced, and the reduction of the components of the range extender can also improve the overall reliability of the range extender.

In some embodiments, the engine crankshaft 1 includes a free end 12, a main journal 11, and an output end 13 that are integrally connected. The engine crankshaft 1 serves to convert the gas forces from the pistons and connecting rods into torque output, driving the rotor assembly 2 connected thereto. The first flange face is arranged on the output end 13, and an annular groove 14 is arranged on the side face of the output end 13, and the annular groove 14 is used for positioning a spigot formed by the engine crankshaft 1 and the engine cylinder body 6. The spigot is positioned such that the engine crankshaft 1 and the engine block 6 can be axially rotated. When the range extender is in operation, the engine crankshaft 1 and the rotor assembly 2 rotate synchronously. To achieve a light weight of the engine crankshaft 1, the output end 13 is provided with a blind hole 15.

In some embodiments, rotor assembly 2 includes a rotor support 21 and a rotor core 22, rotor core 22 being secured to a sidewall of rotor support 21. The rotor holder 21 includes a shaft body 211 and an outer ring body 212, and a second flange surface is provided on an end surface of the outer ring body 212. The shaft body 211 is fixed in the middle of the second flange surface, and the shaft body 211, the second flange surface and the outer ring body 212 are integrally formed. The rotor core 22 is fixed on the side wall of the outer ring body 212, the rotor winding is wound on the rotor core 22, the stator assembly 8 is installed in the generator housing 7, the rotor assembly 2 rotates in the stator assembly 8, and current is generated through electromagnetic induction.

In order to achieve the light weight of the rotor bracket 21, the outer ring body 212 is provided with a plurality of through holes 27 surrounding the shaft body 211. The center of the shaft body 211 is provided with a hollowed hole 28, and the hollowed hole 28 is opposite to the blind hole 15.

In some embodiments, the shaft body 211 has a stepped shaft at an end remote from the output end 13. The step shaft is provided with a rotary transformer 3 and an oil pump 5. Resolver 3 is capable of measuring the position and rotational speed of rotor assembly 2. The rotary transformer 3 is fixed with the step shaft through interference fit or clearance fit, and the fixing mode can be fixed by using a locking nut or a clamping spring. The oil pump 5 provides cooling lubricating oil for the generator, and an external mechanical oil pump, a controller and a power supply can be omitted, so that the reliability of the range extender is improved. Alternatively, the oil pump 5 is a gerotor pump.

In order to achieve a better weight reduction of the rotor holder 21, the hollowed hole 28 has a stepped hole coaxial with the stepped shaft. The inner diameter of each stepped bore decreases simultaneously with the decrease in the outer diameter of the outer stepped shaft.

Applicant has found that when the rotor assembly 2 is directly connected to the engine crankshaft 1, forming a cantilever structure with the engine crankshaft 1, the runout of the engine crankshaft 1 must be amplified on the side of the rotor assembly remote from the engine. Runout includes axial runout and radial runout. The amplification of the runout can cause the uneven degree of the air gap of the generator to be increased, and the concentricity of the stator and the rotor of the rotary transformer 3 to be poor, so that the eccentricity of the inner rotor and the outer rotor of the oil pump is increased, and if the eccentricity exceeds the allowable eccentricity range of the inner rotor and the outer rotor of the oil pump, the oil pump is blocked.

To solve this problem, the range extender further comprises an auxiliary bearing 4, the auxiliary bearing 4 being mounted on the step shaft. The auxiliary bearing 4 is used to support the generator housing 7. Because the engine crankshaft has axial play, the auxiliary bearing needs to bear larger axial force, and cylindrical roller bearings, deep groove ball bearings, cone bearings and the like can be selected. The auxiliary bearing can control radial runout of the end part of the engine crankshaft and can bear axial runout. During assembly, the inner and outer races of the auxiliary bearing are mounted on the step shaft and on the generator housing 7, respectively.

In some embodiments, the stepped shaft includes a first diameter section 24, a second diameter section 25, and a third diameter section 26 that progressively decrease in diameter. Resolver 3 is mounted on first diameter section 24 for measuring the position and rotational speed of rotor assembly 2. The auxiliary bearing 4 is mounted on the second diameter section 25 for supporting the generator housing 7. An oil pump 5 is mounted on the third diameter section 26 for providing cooling oil to the generator.

In some embodiments, as shown in fig. 7, the output end 13 of the engine crankshaft 1 extends into the engine block 6, the rotor assembly 2 is positioned in the generator housing 7, the generator has no front end cover, and the engine block 6 and the generator housing 7 are fixed together, so that the axial length of the range extender can be shortened.

Based on the above, the increase Cheng Qiju proposed by the embodiment of the present invention has the following advantages: compared with the range extender with the spline coupler, the torsional damper and the front end cover of the generator in the prior art, the range extender of the embodiment has no spline coupler, the torsional damper and the front end cover of the generator, so that the cost is reduced, the weight is reduced, the axial length is reduced, parts are reduced, and the assembly process is simpler. The range extender of this embodiment makes the operation of range extender more steady through auxiliary bearing, through the design of coaxial oil pump, makes the generator cooling realize self-loopa, saves external mechanical oil pump, controller and power, and the reliability promotes by a wide margin simultaneously.

It should be noted that in the description of the present invention, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Furthermore, in the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.

In the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; may be mechanically connected, may be electrically connected or may be in communication with each other; either directly or indirectly, through intermediaries, or both, may be in communication with each other or in interaction with each other, unless expressly defined otherwise. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.

In the present invention, unless expressly stated or limited otherwise, a first feature "up" or "down" a second feature may be the first and second features in direct contact, or the first and second features in indirect contact via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.

In the description of the present invention, the azimuth or positional relationship indicated by the terms "left", "right", "front", "rear", etc., are based on the azimuth or positional relationship shown in the drawings, are merely for convenience of description of the present invention and to simplify the description, and do not indicate or imply that the apparatus or element referred to must have a specific azimuth, be constructed and operated in a specific azimuth, and thus should not be construed as limiting the present invention.

Any process or method descriptions in flow charts or otherwise described herein may be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps of the process, and further implementations are included within the scope of the preferred embodiment of the present invention in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present invention.

In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

While embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and not to be construed as limiting the invention, and that variations, modifications, alternatives and variations may be made to the above embodiments by one of ordinary skill in the art within the scope of the invention.

Claims

1. A range extender, comprising:

the engine crankshaft (1), one end of the engine crankshaft (1) is provided with a first flange surface, and the first flange surface is provided with a first connecting hole;

a rotor assembly (2), wherein one end of the rotor assembly (2) is provided with a second flange surface, and the second flange surface is provided with a second connecting hole;

and the fastener (23) is used for connecting the first connecting hole with the second connecting hole so as to fix the engine crankshaft (1) and the rotor assembly (2) together.

2. Range extender according to claim 1, characterized in that the engine crankshaft (1) comprises a free end (12), a main journal (11) and an output end (13) which are integrally connected, the first flange surface being provided on the output end (13).

3. Range extender according to claim 2, characterized in that the output end is provided laterally with an annular groove (14), which annular groove (14) is used for forming a spigot location of the engine crankshaft (1) with the engine block (6).

4. Range extender according to claim 1, characterized in that the rotor assembly (2) comprises a rotor support (21) and a rotor core (22), the rotor core (22) being fixed on a side wall of the rotor support (21).

5. The range extender of claim 4, wherein the rotor bracket (21) includes a shaft body (211) and an outer ring body (212), the second flange surface is disposed on an end surface of the outer ring body (212), and the rotor core (22) is fixed on a side wall of the outer ring body (212).

6. Range extender as claimed in claim 5, characterized in that the outer ring body (212) is provided with a number of through holes (27) surrounding the shaft body (211).

7. Range extender as claimed in claim 5, characterized in that the shaft body (211) has a stepped shaft at the end remote from the output end (13).

8. The range extender of claim 6, wherein the shaft body (211) has a hollowed-out hole (28) in the center, the hollowed-out hole (28) having a stepped hole coaxial with the stepped shaft.

9. The range extender of claim 7, wherein the stepped shaft includes a first diameter section (24), a second diameter section (25), and a third diameter section (26) of progressively decreasing diameter.

10. The range extender of claim 9, further comprising a resolver (3), an auxiliary bearing (4) and an oil pump (5), the resolver (3) being mounted on the first diameter section (24) for measuring the position and rotational speed of the rotor assembly (2); the auxiliary bearing (4) is arranged on the second diameter section (25) and is used for supporting the generator shell (7); the oil pump (5) is mounted on the third diameter section (26) for providing cooling lubricating oil to the generator.