CN117595584A - Electric generator - Google Patents

Abstract

The invention discloses a generator, which comprises a motor shell, wherein an installation space is formed in the motor shell, and an installation groove is concavely formed in one side of the motor shell; the stator and rotor assembly is arranged in the installation space; the controller assembly is electrically connected with the stator and rotor assembly and comprises a controller shell, and the controller shell is installed in the installation groove and is detachably fixed with the motor shell. The controller assembly and the motor shell are detachably fixed, so that the controller assembly and the motor shell can be completely and independently separated, independent production and test can be realized, meanwhile, module replacement can be quickly performed after sales, maintenance and replacement cost is reduced, a plurality of parts such as a three-phase high-voltage wire, a cooling water receiving pipe, a controller cover and the like are reduced, manufacturing cost is saved, product envelope is reduced, power density of the whole generator system is improved, and demand on installation space is reduced.

Description

Electric generator

Technical Field

The present invention relates to the field of vehicle manufacturing, and more particularly to an integrated generator.

Background

The generator is an important part on the automobile, and the main function is to charge the storage battery of the whole automobile, so that the electricity consumption requirement of the whole automobile is met. The working principle of the generator is that when the external circuit makes the exciting winding electrified through the electric brush, a magnetic field is generated, so that the claw pole is magnetized into an N pole and an S pole. When the motor drives the rotor to rotate, magnetic flux alternately changes in the stator windings, and alternating induced electromotive force is generated in the three-phase windings of the stator according to the electromagnetic induction principle.

With the development of technology, environmental protection is being emphasized in more and more industries. In the automotive field, various countries and regions worldwide have announced that fuel vehicles will be banned in the future, and for this reason, more and more manufacturers of whole vehicles have stopped or are about to stop the development of internal combustion engines, and new energy vehicles represented by hybrid power and pure electric forms will be developed greatly. Although the pure electric vehicle is completely free from the constraint of fuel oil, has great advantages in the aspects of driving feeling and the like, the use of the pure electric vehicle is limited by the construction of imperfect supporting facilities, so that the hybrid electric vehicle becomes the first choice of a plurality of consumers, especially home head vehicles.

Unlike a pure electric vehicle, a hybrid vehicle is still equipped with an internal combustion engine, which, depending on the hybrid form, either directly participates in the vehicle drive or only drives a generator to charge a battery. Unlike conventional fuel vehicles, the power generator in the hybrid vehicle has a larger capacity of the battery due to more electrical appliances of the vehicle, and has a larger bearing function and higher requirements on the power generator, and the power generator on the conventional fuel vehicle is not suitable for development of the hybrid vehicle.

The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person of ordinary skill in the art.

Disclosure of Invention

The invention aims to provide an improved generator so as to solve the requirement of a hybrid power vehicle on the generator in the prior art.

In order to achieve the above object, an embodiment of the present invention provides a generator, including a motor housing, in which an installation space is formed, and a mounting groove is concavely formed at one side of the motor housing; the stator and rotor assembly is arranged in the installation space; the controller assembly is electrically connected with the stator and rotor assembly and comprises a controller shell, and the controller shell is matched with the mounting groove and is detachably fixed with the motor shell.

In one or more embodiments of the present invention, the controller assembly further includes a control element electrically connected to the stator and rotor assembly, and the controller housing includes a receiving slot for receiving the control element, and/or the controller housing is in contact with the contact surface of the motor housing.

In one or more embodiments of the present invention, the stator and rotor assembly includes a plug protruding from an edge of one side of the mounting groove, and a socket that is plugged with the plug in a mating manner is disposed on one side of the controller housing, and the socket is electrically connected with the control element.

In one or more embodiments of the present invention, the controller housing is provided with a heat dissipation window communicating with the receiving groove, and/or the outer surface of the controller housing is provided with a first heat dissipation rib.

In one or more embodiments of the present invention, the controller housing includes a first liquid inlet, a first liquid outlet, and a cooling channel communicating the first liquid inlet and the first liquid outlet.

In one or more embodiments of the present invention, the motor further comprises a water jacket disposed in the installation space, the water jacket comprises a second liquid inlet and a second liquid outlet, a third liquid inlet and a third liquid outlet which are communicated with the installation space are formed in the motor housing, the second liquid inlet is communicated with the external space through the third liquid inlet, and the second liquid outlet is communicated with the external space through the third liquid outlet.

In one or more embodiments of the present invention, the controller housing includes a first liquid inlet, a first liquid outlet, and a cooling channel communicating the first liquid inlet and the first liquid outlet, the first liquid outlet communicating with the second liquid inlet through a third liquid inlet.

In one or more embodiments of the present invention, the water jacket abuts between the stator and rotor assembly and the motor housing.

In one or more embodiments of the present invention, the motor housing may have second heat dissipating ribs provided on an outer surface thereof, and/or the mounting groove may have third heat dissipating ribs protruding from an inner surface thereof.

In one or more embodiments of the invention, the stator and rotor assembly includes splines extending out of the motor housing, the splines being on opposite sides of the motor housing from the controller assembly.

Compared with the prior art, the generator according to the embodiment of the invention has the advantages that the controller assembly and the motor shell are detachably fixed, so that the controller assembly and the motor shell can be completely and independently separated, independent production and test can be realized, meanwhile, after-sale module replacement can be quickly performed, the maintenance and replacement cost is reduced, meanwhile, a plurality of parts such as three-phase high-voltage wires, cooling water receiving pipes, a controller cover and the like are reduced, the manufacturing cost is saved, meanwhile, the product envelope is reduced, the power density of the whole generator system is improved, and the requirement on the installation space is reduced.

Drawings

FIG. 1 is a front view of a generator according to an embodiment of the present invention;

FIG. 2 is a side view of a generator according to an embodiment of the invention;

FIG. 3 is a top view of a generator according to an embodiment of the invention;

FIG. 4 is an exploded view of a generator according to an embodiment of the present invention;

FIG. 5 is a partially disassembled view of a generator according to an embodiment of the invention;

FIG. 6 is a partially disassembled view of another angle of a generator according to an embodiment of the present invention;

fig. 7 is a schematic view of a water jacket according to an embodiment of the present invention.

The main reference numerals illustrate:

the device comprises a 100-generator, a 10-motor shell, a 11-second mounting ring, a 12-second heat radiating rib, a 13-third liquid inlet, a 14-third liquid outlet, a 15-third heat radiating rib, a 16-cover plate, a 161-fourth heat radiating rib, a 20-controller assembly, a 21-controller shell, a 211-first mounting ring, a 212-first liquid inlet, a 213-first liquid outlet, a 214-first heat radiating rib, a 215-containing groove, a 216-heat radiating window, a 217-connection socket, a 22-control element, a 30-stator-rotor assembly, 31-splines, 32-plugs, 40-water jackets, 41-second liquid inlets and 42-second liquid outlets.

Detailed Description

In order to better understand the technical solutions in the present application, the following description 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, and it is obvious that the described embodiments are only some embodiments of the present application, not all embodiments. All other embodiments, which can be made by one of ordinary skill in the art based on the embodiments herein without making any inventive effort, shall fall within the scope of the present application.

In the description of the present invention, it should be understood that the terms "upper," "lower," and the like indicate an orientation or a positional relationship, and are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.

In the present specification, each embodiment is described in a progressive manner, and each embodiment focuses on a difference from other embodiments, and the same or similar parts between the embodiments are referred to each other.

It should be noted that the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation. The term "comprising" an element defined by the term "comprising" does not exclude the presence of other identical elements in a process, method, article or apparatus that comprises the element.

In recent years, carbon neutralization has become a hot topic on a global scale, and with the increasing progress of climate change and sustainable development of call, carbon neutralization is considered as one of important means for reducing greenhouse gas emissions and protecting the environment. Compared with the traditional fuel oil vehicle, the new energy vehicle represented by the pure electric vehicle and the hybrid electric vehicle has the characteristics of zero/low emission and low energy consumption, and has important significance for realizing the carbon neutralization target. But the construction of the matched energy supplementing facilities is not perfect at present, and the use of the pure electric automobile is limited. Therefore, hybrid vehicles are the first choice for many consumers with inconvenient energy supply.

Unlike a pure electric vehicle, the hybrid electric vehicle still carries an internal combustion engine, and the internal combustion engine directly participates in the vehicle driving or only drives a generator to charge a storage battery according to the different hybrid power modes, so that the vehicle is driven by a driving motor to run. Unlike the conventional fuel oil vehicles, with the development of technology, the number of electric appliances carried by the vehicles is increased, the electricity demand is increased, and the capacity of the storage battery is increased continuously, so that the requirements on the vehicle-mounted generator are also increased.

In any hybrid generator, the rotor is driven by the engine to rotate, and magnetic flux is alternately changed in the stator winding, so that alternating induced electromotive force is generated and electric energy is generated. The generator controller is used for automatically controlling the generator voltage to keep constant when the rotation speed of the generator changes, preventing the electric equipment and the storage battery from being damaged due to the fact that the generator voltage is too high, and simultaneously preventing the power supply equipment from working abnormally and the battery from being charged insufficiently due to the fact that the generator voltage is too low. In conventional fuel-fired vehicle generators, the controller is typically integrated on the generator body, although the fixing effect is better, the generator body is found to be significantly lower in damage or failure probability than the controller through a large number of maintenance and replacement cases, but the whole generator assembly needs to be replaced due to the integrated design, so that the cost is high, and resource waste is easily caused.

In this regard, the present invention proposes an improved generator 100, as shown in fig. 1 to 7, mainly comprising a motor housing 10, a controller assembly 20, and a stator-rotor assembly 30, wherein the stator-rotor assembly 30 is disposed in an installation space in the motor housing 10, and the rotor portion is driven by an engine to rotate relative to the stator portion, so as to convert mechanical energy into electrical energy.

Unlike the conventional generator, in this embodiment, the controller assembly 20 and the motor housing 10 are detachably fixed, so that the controller assembly can be individually replaced when the main body part or the controller part is failed or damaged and needs to be maintained, thereby reducing the cost and avoiding the waste of resources.

As shown in fig. 5 in particular, a mounting groove structure is formed on the outer surface of the motor housing 10 at a position corresponding to the controller assembly 20, and the controller housing 21 is correspondingly mounted in the mounting groove region.

Further, in order to improve the installation effect between the motor housing 10 and the controller housing 21, the contact surfaces of the motor housing 10 and the controller housing 21 are attached, a second mounting ring 11 is formed on the periphery of the installation groove of the motor housing 10, the second mounting ring 11 is formed on one side facing the controller assembly 20 and protrudes outwards, a first mounting ring 211 is also formed on the controller housing 21, and the two mounting rings are contact surfaces between the two housings, have the same shape and can be tightly attached, so that the controller assembly 20 can be tightly attached and fixed on the motor housing 10 in a common bolt fixing mode, the fixing effect is good, and no gap exists.

Preferably, during the installation process, a sealant may be applied between the first mounting ring 211 and the second mounting ring 11, so as to further improve the sealing performance, prevent water or other foreign matters from entering, affect the performance of the controller assembly 20, even cause failure or damage, and the like, and ensure stability.

As shown in fig. 6, the controller housing 21 is formed with a receiving groove 215, and the control element 22 is fixed in the receiving groove 215 and electrically connected with the stator and rotor assembly 30 to control the output voltage and current, thereby avoiding damaging the battery or the vehicle-mounted electric appliance. The accommodating groove 215 is located in the range of the first mounting ring 211, and directly faces the motor housing 10, and is not in a closed design, so that the number of components of the controller assembly 20, such as three-phase high-voltage wires, cooling water receiving pipes, a controller cover and the like, is further reduced, the manufacturing cost is reduced, the product envelope is synchronously reduced, the power density of the whole generator 100 is improved, the requirement on the mounting space is reduced, and the hybrid system is more suitable.

As shown in fig. 5, the plug 32 electrically connected to the stator and rotor assembly 30 and the controller assembly 20 protrudes into the mounting groove (i.e., the range of the first mounting ring 211) of the motor housing 10, and a corresponding socket (not shown) is provided in the controller housing 21, so that the connection between the control element 22 and the stator and rotor assembly 30 is also completed during the process of mounting the controller assembly 20, the operation steps are reduced, and the mounting efficiency is improved.

The vehicle generator can generate heat in the working process, and the generator needs to be cooled in order to ensure normal work. The traditional vehicle generator generally adopts an air-cooled cooling mode, namely, a generator shell adopts a hollowed-out mode, and air flow directly enters the generator to dissipate heat. Because the shell is hollowed out, foreign matters possibly enter in the working process to influence the normal operation, and the hotter environment possibly also influences the normal operation of the generator.

Therefore, the generator 100 in this embodiment adopts a liquid cooling mode, and the controller assembly 20 is also cooled to ensure the working effect. As shown in fig. 5 and 6, a first liquid inlet 212 and a first liquid outlet 213 are formed in the controller housing 21, and a cooling channel (not shown) is formed therein. Cooling water (which may be other cooling liquid and is not described herein) flows out through the first liquid outlet 213 after entering the cooling channel through the first liquid inlet 212, thereby taking away the heat to ensure the working temperature of the controller assembly 20 and reducing the probability of failure or damage.

Meanwhile, a water jacket 40 is provided in the controller housing 21, and the water jacket 40 surrounds between the stator and rotor assembly 30 and the inner wall of the controller housing 21 to dissipate heat. Preferably, the water jacket 40 is communicated with the cooling channel of the controller housing 21, the cooling water flows through the controller housing 21 and then enters the motor housing 10 to cool the motor housing, and finally the cooling water flows out and enters the water tank to dissipate heat.

As shown in fig. 5, 6 and 7, the water jacket 40 includes a second liquid inlet 41 and a second liquid outlet 42, a third liquid inlet 13 and a third liquid outlet 14 are provided on the motor housing 10, the second liquid inlet 41 is communicated with the first liquid outlet 213 through the third liquid inlet 13, and the second liquid outlet 42 is communicated with the external space through the third liquid outlet 14. Thus, a complete cooling circuit is formed between the motor housing 10 and the controller assembly 20, and cooling water flows in through the first liquid inlet 212, flows through the controller housing 21 and the motor housing 10, and then flows out through the third liquid outlet 14.

Preferably, the first liquid outlet 213 is formed on the first mounting ring 211, and the third liquid inlet 13 is formed on the second mounting ring 11, and the two mounting rings can be tightly attached, so that the third liquid inlet 13 can be directly abutted against the first liquid outlet 213, which is more convenient when the cooling pipeline is connected.

The generator 100 is connected to the vehicle battery through a connection socket 217, and the connection socket 217 and the first liquid inlet 212 are separately provided at both sides of the controller housing 21, so as to avoid the risk of cooling water falling on the connection socket 217 due to leakage occurring at the first liquid inlet 212.

In the above arrangement mode, only one cooling loop exists between the generator 100 and the water tank, so that the whole wiring is simpler and the cost is lower. Of course, a mode of cooling both the motor housing 10 and the controller assembly 20 independently may be selected, that is, both are respectively connected to the water tank for cooling, and two cooling circuits are provided between the generator 100 and the water tank.

Generally, the cooling water flows into the water tank to dissipate heat by the fan, and in this embodiment, a plurality of first heat dissipating ribs 214 are further formed on the outer surface of the controller housing 21, so as to assist in dissipating heat by increasing the contact area between the controller housing 21 and air, thereby improving the heat dissipating effect. As can be seen from fig. 5, the first heat dissipating ribs 214 have a crossed "well" structure.

In order to further improve the heat dissipation effect of the controller housing 21, a heat dissipation window 216 communicating with the internal accommodating groove 215 is further provided in the controller housing 21. In summary, the heat in the accommodating groove 215 can be taken away by three heat dissipation modes, one is the cooling water in the cooling pipeline; secondly, the heat dissipation ribs 214 are further transferred to the external space after being transferred to the body of the controller shell 21, so that the contact area between the heat dissipation ribs and air can be increased, and the heat dissipation effect can be improved; and thirdly, the air is directly discharged to the external space through the heat dissipation window 216. By providing multiple heat dissipation modes, the controller housing 21 can be controlled within a reasonable temperature range, further reducing the probability of damage.

In the present embodiment, the water jacket 40 is interposed between and in contact with the stator and rotor assembly 30 and the inner wall of the motor housing 10, respectively, so that heat of the stator and rotor assembly 30 can be directly transferred to the internal cooling water through the surface of the water jacket 40. Meanwhile, the motor shell 10 is clung to the inner wall of the motor shell 10, so that the motor shell 10 can also take away part of heat of the water jacket 40, a plurality of second heat dissipation ribs 12 are arranged on the outer surface, the contact area with air is increased through the second heat dissipation ribs 12, auxiliary heat dissipation is carried out, the heat dissipation effect is improved, and the second heat dissipation ribs 12 are arranged on the side face of the motor shell 10 in an array mode.

Meanwhile, the third heat sink rib 15 is also provided in the mounting groove (i.e., in the range of the first mounting ring 11), so that part of the heat can be transferred to the external space through the controller housing 21. And as shown in fig. 5, the third heat sink rib 15 includes a portion radiating outward from the center and a circular portion, so the third heat sink rib 15 is in a spider-web structure as a whole.

As shown in fig. 6, the stator-rotor assembly 30 has a spline 31 protruding to the outside of the motor housing 10, and the generator 10 is directly connected with the vehicle engine through the spline 31, so that compared with the conventional belt pulley and belt transmission, the direct-drive generator reduces transmission loss, improves transmission efficiency, and can integrate the generator 100 at one side of the engine, thereby reducing space occupation of the engine compartment and improving space utilization.

In order to facilitate the placement of the stator and rotor assembly 30 and the water jacket 40, a detachable cover plate 16 is provided on the other side of the motor housing 10, and a hole is formed in the center of the cover plate 16 for the spline 31 to extend. The cover plate 16 is also provided with fourth heat radiation ribs 161 which are in the same spider-web form as the third heat radiation ribs 15, and which are convenient for the operator to take when the heat radiation effect is improved by increasing the contact area with the air. Meanwhile, since the side has no other parts except the spline 31, the fourth heat dissipation ribs 161 can occupy more surface space of the cover plate 16, so that more annular heat dissipation ribs can be arranged, the contact area with air is larger, and the heat dissipation effect is better.

The foregoing descriptions of specific exemplary embodiments of the present invention are presented for purposes of illustration and description. It is not intended to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain the specific principles of the invention and its practical application to thereby enable one skilled in the art to make and utilize the invention in various exemplary embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims and their equivalents.

Claims (10)

1. A generator, comprising:

a motor shell, wherein an installation space is formed in the motor shell, and an installation groove is concavely formed in one side of the motor shell;

the stator and rotor assembly is arranged in the installation space;

the controller assembly is electrically connected with the stator and rotor assembly and comprises a controller shell, and the controller shell is matched with the mounting groove and is detachably fixed with the motor shell.

2. The generator of claim 1, wherein the controller assembly further comprises a control element electrically connected to the stator and rotor assembly, the controller housing comprises a receiving slot for receiving the control element, and/or

And the contact surfaces of the controller shell and the motor shell are attached.

3. The generator of claim 2, wherein the stator and rotor assembly comprises a plug protruding from an edge of one side of the mounting groove, a socket matched with the plug and inserted into one side of the controller housing is arranged on one side of the controller housing, and the socket is electrically connected with the control element.

4. The generator of claim 2, wherein the controller housing is provided with a heat dissipation window communicating with the accommodation groove, and/or

The outer surface of the controller shell is provided with first radiating ribs.

5. The generator of claim 1, wherein the controller housing includes a first liquid inlet, a first liquid outlet, and a cooling channel communicating the first liquid inlet and the first liquid outlet.

6. The generator of claim 1, further comprising a water jacket disposed in the mounting space, the water jacket including a second liquid inlet and a second liquid outlet, the motor housing having a third liquid inlet and a third liquid outlet in communication with the mounting space, the second liquid inlet in communication with the external space through the third liquid inlet, and the second liquid outlet in communication with the external space through the third liquid outlet.

7. The generator of claim 6, wherein the controller housing includes a first fluid inlet, a first fluid outlet, and a cooling channel communicating the first fluid inlet and the first fluid outlet, the first fluid outlet communicating with the second fluid inlet through a third fluid inlet.

8. The generator of claim 6, wherein the water jacket abuts between the stator and rotor assemblies and the motor housing.

9. The generator of claim 1, wherein the outer surface of the motor housing is provided with second heat dissipating ribs, and/or

And the inner surface of the mounting groove is convexly provided with a third radiating rib.

10. The generator of claim 1 wherein said stator and rotor assembly includes splines extending out of said motor housing, said splines being on opposite sides of said motor housing from a controller assembly.