CN215498609U - Range extender structure with motor cavity isolated from junction box cavity - Google Patents

Abstract

The utility model discloses a range extender structure with a motor cavity isolated from a junction box cavity, which comprises a motor shell, a rotor bracket, a rotor assembly, a stator assembly, an end cover, a rotary transformer, a bearing and an output assembly, wherein the motor shell is provided with a rotor; one end of the motor shell is fixedly connected with the engine body, and the other end of the motor shell is fixedly connected with the end cover; one end of the rotor bracket is coaxially and fixedly connected with a crankshaft of the engine, and the other end of the rotor bracket is protruded with an output assembly coaxially and fixedly connected with the rotor bracket; the output assembly comprises an output shaft and an output gear, and a bearing and a rotating end of the rotary transformer are sequentially fixedly sleeved on an outer ring of the output shaft; the outer ring of the motor shell is also fixedly provided with a junction box, a cover plate is fixedly arranged between the junction box and the motor cavity, and the junction box and the motor cavity are sealed and isolated by the cover plate; and a cooling water channel is also arranged in the side wall of the motor shell. The range extender structure with the motor cavity isolated from the junction box cavity has high energy utilization rate, cooling efficiency and reliability.

Description

Range extender structure with motor cavity isolated from junction box cavity

Technical Field

The utility model relates to a motor structure, in particular to a range extender structure with a motor cavity isolated from a junction box cavity.

Background

At present, in order to increase the endurance mileage of a pure electric vehicle, an extended range electric vehicle becomes a new energy vehicle development trend, and the extended range electric vehicle can use an engine to supply electric energy under the condition of insufficient battery power. The conventional range extender is connected with a motor rotor through an engine crankshaft, and converts energy generated by an engine into electric energy to charge a battery, so that the endurance mileage of the electric automobile is improved.

In the prior art, for example, chinese patent CN108995542A discloses a range extender for an electric vehicle with an integrated motor, which includes: an engine body; an engine output shaft; a connecting plate; a generator; the generator comprises a rotary transformer, a motor rotor assembly, a motor stator assembly, a motor shell and a motor rear cover plate, wherein the motor shell is fixed on the connecting plate, and the motor stator assembly is put into the motor shell from the front end of the motor shell and is sleeved on the motor shell in a hot mode; the motor rotor assembly is coaxially disposed within the motor stator assembly and has a motor rotor support that extends into the connection plate and is directly connected to the engine output shaft, the resolver comprising: a resolver stator and a resolver rotor. Although the compactness and the stability of the whole structure are improved in the prior art, the energy utilization rate and the motor space utilization rate of the structure are lower, the cooling effect and the motor operation reliability are poor, and the motor output cable is poor in sealing performance and inconvenient to maintain.

SUMMERY OF THE UTILITY MODEL

Aiming at the problems, the utility model provides a range extender structure with a motor cavity isolated from a junction box cavity, aiming at solving the problems of lower energy utilization rate and motor space utilization rate, poor cooling effect and motor operation reliability, poor sealing performance of a motor output cable, inconvenience in maintenance and the like in the existing motor structure.

The utility model adopts the following technical scheme to realize the purpose:

a range extender structure with a motor cavity isolated from a junction box cavity is used for being installed in a matching way with an engine and comprises a motor shell, a rotor bracket, a rotor assembly, a stator assembly, an end cover, a rotary transformer, a bearing and an output assembly; one end of the motor shell is fixedly connected with the engine body, and the other end of the motor shell is fixedly connected with the end cover; a first through hole is formed in one end, connected with the engine body, of the motor shell, and a second through hole penetrating through the end face of the end cover is formed in the end cover; one end of the rotor bracket is coaxially and fixedly connected with a crankshaft of an engine, the crankshaft of the engine penetrates through the through hole, the end of the rotor bracket is also in transmission connection with a starting gear ring, the rotor assembly is fixedly arranged on an outer ring of the rotor bracket, and an output assembly coaxially and fixedly connected with the rotor bracket is protruded from the other end of the rotor bracket; the output assembly comprises an output shaft and an output gear, one end of the output shaft is coaxially and fixedly connected with the rotor bracket, and the other end of the output shaft penetrates through a second through hole of the end cover and is coaxially and fixedly connected with the output gear; the outer ring of the output shaft is sequentially fixedly sleeved with a bearing and a rotating end of a rotary transformer; the outer ring of the bearing is matched with the inner ring of the second through hole, and the fixed end of the rotary transformer is fixedly arranged on the inner ring of the second through hole; the stator assembly is fixedly arranged on the side wall of the motor shell opposite to the rotor assembly; the outer ring of the motor shell is also fixedly provided with a junction box which is used for connecting an output line inside the motor shell; a cover plate is fixedly arranged between the junction box and the motor cavity and seals and isolates the junction box from the motor cavity; and a cooling water channel is further arranged in the side wall of the motor shell and is of one of a multi-ring type, single-ring type or spiral type structure.

In the technical scheme, the motor is rigidly and directly connected with the crankshaft of the engine, the structure is simple, the flywheel shell and the motor shell are integrated, the length of the motor is shortened, and the rotor support is in transmission connection with the starting gear ring, so that the energy utilization rate is improved; the cooling water channel is additionally arranged in the side wall of the motor shell, so that the serious heat accumulation of the motor due to the narrow position in the structure is avoided, particularly the heat loss when an automobile is started or stopped or is in a high-torque low-torque transfer state for a long time is avoided, the endurance mileage of a battery and the service life of the motor are greatly improved, the cooling performance of the motor is effectively improved, and the running stability of the motor is improved; the rotor bracket is connected with the output assembly and extends out of the end cover, so that the functions of power generation, spline shaft output and simultaneous power generation can be considered, and the spline shaft output function is realized, and the space utilization rate and the energy utilization rate of the motor are improved; the junction box is matched with the cover plate to realize a structure that the motor cavity and the junction box cavity are separated, so that the conditions in the two cavities are not influenced mutually, and dustproof and waterproof measures can be respectively designed for the junction box and the motor cavity, so that the waterproof and dustproof performance of the system is improved; in addition, due to the separation of the motor cavity and the junction box cavity, the replacement of the three-phase line is more rapid and convenient, and the difficulty in maintenance is greatly reduced.

The further technical scheme is that one end of the motor shell is fixedly connected with the engine through a fixing bolt.

The further technical scheme is that the end cover extends to the end part of the junction box and is fixedly connected with the side wall of the junction box, and the cover plate is respectively connected with the outer side wall of the motor shell and the inner side wall of the junction box in a sealing manner; the side wall of the motor shell between the cover plate and the end cover is provided with a wiring through hole; the cover plate is also provided with a sealing wiring hole.

The further technical scheme is that one end of the rotor support, which is close to the end cover, is fixedly provided with a compression ring matched with the rotor assembly.

The utility model has the beneficial effects that:

according to the range extender structure with the motor cavity and the junction box cavity isolated, the motor is rigidly and directly connected with the crankshaft of the engine, the structure is simple, the flywheel shell and the motor shell are integrated, the length of the motor is shortened, and the rotor support is in transmission connection with the starting gear ring, so that the energy utilization rate is improved; the cooling water channel is additionally arranged in the side wall of the motor shell, so that the serious heat accumulation of the motor due to the narrow position in the structure is avoided, particularly the heat loss when an automobile is started or stopped or is in a high-torque low-torque transfer state for a long time is avoided, the endurance mileage of a battery and the service life of the motor are greatly improved, the cooling performance of the motor is effectively improved, and the running stability of the motor is improved; the rotor bracket is connected with the output assembly and extends out of the end cover, so that the functions of power generation, spline shaft output and simultaneous power generation can be considered, and the spline shaft output function is realized, and the space utilization rate and the energy utilization rate of the motor are improved; the junction box is matched with the cover plate to realize a structure that the motor cavity and the junction box cavity are separated, so that the conditions in the two cavities are not influenced mutually, and dustproof and waterproof measures can be respectively designed for the junction box and the motor cavity, so that the waterproof and dustproof performance of the system is improved; in addition, due to the separation of the motor cavity and the junction box cavity, the replacement of the three-phase line is more rapid and convenient, and the difficulty in maintenance is greatly reduced.

Drawings

FIG. 1 is a diagram: the utility model discloses a structural schematic diagram of a range extender with a motor cavity isolated from a junction box cavity.

FIG. 2 is a diagram of: the utility model discloses a structural schematic diagram of a multi-ring cooling water channel.

FIG. 3 is a diagram of: the utility model discloses a schematic structure diagram of a single-ring cooling water channel.

FIG. 4 is a diagram of: the utility model discloses a structural schematic diagram of a spiral cooling water channel.

In the figure:

1. an engine; 2. a crankshaft; 3. fixing the bolt; 4. a motor housing; 41. a multi-ring cooling water channel; 42. a single-ring cooling water channel; 43. a spiral cooling water channel; 5. a rotor support; 6. a rotor assembly; 61. pressing a ring; 7. a stator assembly; 8. a junction box; 81. a wiring copper bar; 82. a cover plate; 83. an output line; 9. an end cap; 10. a rotary transformer; 11. a bearing; 12. an output component; 13. the ring gear is started.

Detailed Description

The utility model is described in detail below with reference to fig. 1 to 4 and the embodiments, and features of the following examples and examples may be combined with each other without conflict.

As shown in fig. 1 to 4, the present embodiment provides a range extender structure with a motor cavity isolated from a terminal box cavity, which is used for being installed in cooperation with an engine 1, and includes a motor casing 4, a rotor bracket 5, a rotor assembly 6, a stator assembly 7, an end cover 9, a rotary transformer 10, a bearing 11, and an output assembly 12; one end of the motor shell 4 is fixedly connected with the engine body of the engine 1, and the other end of the motor shell is fixedly connected with the end cover 9; a first through hole is formed in one end, connected with the engine body of the engine 1, of the motor shell 4, and a second through hole penetrating through the end face of the end cover 9 is formed in the end cover; one end of the rotor bracket 5 is coaxially and fixedly connected with a crankshaft 2 of the engine 1, the crankshaft 2 of the engine 1 penetrates through the through hole, the end of the rotor bracket 5 is also in transmission connection with a starting gear ring 13, the rotor assembly 6 is fixedly arranged on an outer ring of the rotor bracket 5, and an output assembly 12 coaxially and fixedly connected with the other end of the rotor bracket 5 protrudes out of the other end of the rotor bracket 5; the output assembly 12 comprises an output shaft and an output gear, one end of the output shaft is coaxially and fixedly connected with the rotor bracket 5, and the other end of the output shaft penetrates through a second through hole of the end cover 9 and is coaxially and fixedly connected with the output gear; the outer ring of the output shaft is sequentially fixedly sleeved with a bearing 11 and a rotating end of a rotary transformer 10; the outer ring of the bearing 11 is matched with the inner ring of the second through hole, and the fixed end of the rotary transformer 10 is fixedly arranged on the inner ring of the second through hole; the stator assembly 7 is fixedly arranged on the side wall of the motor shell 4 opposite to the rotor assembly 6; the outer ring of the motor shell 4 is also fixedly provided with a junction box 8 for connecting an output line 83 inside the motor shell 4; a cover plate 82 is fixedly arranged between the junction box 8 and the motor cavity, and the junction box 8 is sealed and isolated from the motor cavity by the cover plate 82; a multi-ring cooling water channel 41 is further arranged inside the side wall of the motor shell 4;

specifically, rotor subassembly 6 is the magnet steel, and stator module 7 is the wire winding subassembly, and rotor support 5 is one end open-ended hollow structure, and the directional end cover 9 of opening, rotor support 5, second through-hole, output shaft and 2 coaxial laying of bent axle, and apron 82 is terminal box 8 and the sealed concrete structure of keeping apart of motor cavity: the end cover 9 extends to the end part of the junction box 8 and is fixedly connected with the side wall of the junction box 8, and the cover plate 82 is respectively connected with the outer side wall of the motor shell 4 and the inner side wall of the junction box 8 in a sealing manner; a wiring through hole is formed in the side wall of the motor shell 4 between the cover plate 82 and the end cover 9; the cover plate 82 is also provided with a sealing wiring hole; the inner side wall of the junction box 8, the outer side wall of the motor shell 4 and the cover plate 82 are enclosed to form a sealed wiring cavity, the wiring through hole in the side wall of the motor shell 4 is communicated with the inside of the motor shell 4, the end cover 9, the cover plate 82 and the side wall of the junction box 8 are enclosed to form a sealed wiring cavity of a motor output line 83, the wiring hole in the cover plate 82 is used for threading the output line 83, and the wiring cavity is connected with a wiring copper bar 81 in the wiring cavity to form a conductive loop for outputting electric energy; wherein, the wiring hole on the cover plate 82 is internally provided with a rubber sleeve which is in interference fit with the output line 83 to play a role of sealing;

the specific installation process of the embodiment is as follows: a stator component 7 is fixedly arranged on the inner side wall of a motor shell 4, a rotor component 6 is fixedly arranged on the outer ring of a rotor bracket 5, the motor shell 4 is fixedly arranged on the engine body of an engine 1 through a fixing bolt 3, a crankshaft 2 penetrates through a first through hole on the end surface of the motor shell 4 and is coaxially and fixedly connected with the rotor bracket 5, the rotor component 6 and the stator component 7 are positioned on a matched position, the rotor bracket 5 and a starting gear ring 13 are positioned on a meshed position, a motor output line 83 penetrates through a wiring hole of a cover plate 82 and is electrically connected with a wiring copper bar 81 in a junction box 8, a sealing mounting cover plate 82 is arranged on the inner side wall of the junction box 8 and the outer side wall of the motor shell 4, one end of the output shaft and the rotor bracket 5 are coaxially and fixedly arranged, a bearing 11 and a fixed end of a rotary transformer 10 are sequentially arranged on the inner ring of a second through hole of an end cover 9, wherein a bearing mounting seat protruding towards the interior of the motor shell 4 can be arranged at the second through hole, the outer ring of the bearing 11 is fixedly connected with the inner ring of the bearing mounting seat, the end cover 9 is fixedly connected with the end part of the motor casing 4, the output shaft penetrates through the second through hole, the outer ring of the output shaft is fixedly connected with the inner ring of the bearing 11, the rotating end of the rotary transformer 10 is sleeved at the matching position of the outer ring of the output shaft and the fixed end of the rotary transformer 10, and finally the output gear is coaxially and fixedly mounted at the other end of the output shaft, wherein in the embodiment, the end cover 9 extends to the side wall of the junction box 8 and is fixedly connected with the side wall of the junction box 8, and a wiring through hole is formed between the end cover 9 and the side wall of the motor casing 4 at the position of the junction box 8. In addition, parts such as wire winding subassembly, magnet steel, bearing can carry on spacingly through limit structure such as clamping ring or boss after the installation is accomplished, further improve the reliability of motor. Force transmission path: the engine crankshaft outputs power, the motor generates power, electric energy is output to the motor controller through the output cable, and finally the electric energy is output to the whole vehicle through the motor controller for use.

In the above connection manner, the fixed connection includes, but is not limited to, fixing by means of fixing bolts, gluing, welding, snapping, or tight fitting; the sealing connection includes, but is not limited to, fixing the connection by a sealant, disposing a rubber gasket at the connection, and the like, and in other embodiments, the specific structure of the cover plate 82 for sealing and isolating the junction box 8 from the motor cavity may be replaced by other methods, for example: between apron 82 sealed mounting and motor casing 4 tip and end cover 9, through sealed glue or sealed sealing gasket sealing connection between end cover 9 and the terminal box 8, or motor casing 4 lateral wall is equipped with the line through-hole that link up, communicates with terminal box 8, at this line through-hole sealed mounting apron 82, can obtain sealed wiring chamber and with the inside line chamber of walking that communicates of motor casing 4 with the same principle.

It is worth to be noted that, the cooling water channel inside the side wall of the motor casing 4 is designed to be integrally formed and is formed by one-step casting with the motor casing 4, the two ends of the multi-ring cooling water channel 41 inside the side wall of the motor casing 4 are respectively provided with a water inlet and a water outlet, and the water inlet and the water outlet are respectively communicated with the water channel outside the motor casing 4, so that the cooling performance of the motor is effectively improved, and the stability of the motor in operation is improved, in other embodiments or practical applications, a single-ring cooling water channel 42 or a spiral cooling water channel 43 can be adopted, as shown in fig. 3 and 4; the motor is rigidly and directly connected with a crankshaft 2 of the engine 1, the structure is simple, the flywheel housing and the motor housing 4 are integrated, the length of the motor is shortened, and the rotor support 5 is in transmission connection with the starting gear ring 13, so that the energy utilization rate is improved; the rotor bracket 5 is connected with the output assembly 12 and extends out of the end cover 9, so that the functions of power generation, spline shaft output and simultaneous power generation can be considered, and the spline shaft output function is realized, and the space utilization rate and the energy utilization rate of the motor are improved; the junction box 8 is matched with the cover plate 82 to realize a structure that a motor cavity and a junction box cavity are separated, so that the conditions in the two cavities are not influenced mutually, and dustproof and waterproof measures can be respectively designed for the junction box 8 and the motor cavity, so that the waterproof and dustproof performance of the system is improved; in addition, due to the separation of the motor cavity and the junction box cavity, the replacement of the three-phase line is more rapid and convenient, and the difficulty in maintenance is greatly reduced.

In a preferred embodiment, a compression ring 61 matched with the rotor assembly 6 is fixedly arranged at one end of the rotor bracket 5 close to the end cover 9, so that the stability of the rotor assembly 6 can be further ensured.

According to the range extender structure with the motor cavity and the junction box cavity isolated, the motor is rigidly and directly connected with the crankshaft 2 of the engine 1, the structure is simple, the flywheel shell and the motor shell 4 are integrated, the length of the motor is shortened, and the rotor support 5 is in transmission connection with the starting gear ring 13, so that the energy utilization rate is improved; the cooling water channel is additionally arranged in the side wall of the motor shell 4, so that the serious heat accumulation of the motor due to the narrow position in the structure is avoided, particularly the heat loss when an automobile is started or stopped or is in a high-torque low-torque transfer state for a long time is avoided, the endurance mileage of a battery and the service life of the motor are greatly improved, the cooling performance of the motor is effectively improved, and the running stability of the motor is improved; the rotor bracket 5 is connected with the output assembly 12 and extends out of the end cover 9, so that the functions of power generation, spline shaft output and simultaneous power generation can be considered, and the spline shaft output function is realized, and the space utilization rate and the energy utilization rate of the motor are improved; the junction box 8 is matched with the cover plate 82 to realize a structure that a motor cavity and a junction box cavity are separated, so that the conditions in the two cavities are not influenced mutually, and dustproof and waterproof measures can be respectively designed for the junction box and the motor cavity, so that the waterproof and dustproof performance of the system is improved; in addition, due to the separation of the motor cavity and the junction box cavity, the replacement of the three-phase line is more rapid and convenient, and the difficulty in maintenance is greatly reduced.

Claims (4)

1. A range extender structure with a motor cavity isolated from a junction box cavity is used for being installed in a matched manner with an engine (1), and is characterized by comprising a motor shell (4), a rotor bracket (5), a rotor assembly (6), a stator assembly (7), an end cover (9), a rotary transformer (10), a bearing (11) and an output assembly (12); one end of the motor shell (4) is fixedly connected with the engine body of the engine (1), and the other end of the motor shell is fixedly connected with the end cover (9); one end of the motor shell (4) connected with the engine body of the engine (1) is provided with a first through hole, and the end cover (9) is provided with a second through hole penetrating through the end face of the end cover;

one end of the rotor support (5) is coaxially and fixedly connected with a crankshaft (2) of an engine (1), the crankshaft (2) of the engine (1) penetrates through the through hole, the end of the rotor support (5) is also in transmission connection with a starting gear ring (13), the rotor assembly (6) is fixedly installed on an outer ring of the rotor support (5), and an output assembly (12) coaxially and fixedly connected with the rotor support (5) protrudes from the other end of the rotor support;

the output assembly (12) comprises an output shaft and an output gear, one end of the output shaft is coaxially and fixedly connected with the rotor bracket (5), and the other end of the output shaft penetrates through a second through hole of the end cover (9) and is coaxially and fixedly connected with the output gear; the outer ring of the output shaft is sequentially fixedly sleeved with a bearing (11) and a rotating end of a rotary transformer (10); the outer ring of the bearing (11) is matched with the inner ring of the second through hole, and the fixed end of the rotary transformer (10) is fixedly arranged on the inner ring of the second through hole;

the stator assembly (7) is fixedly arranged on the side wall of the motor shell (4) opposite to the rotor assembly (6);

the outer ring of the motor shell (4) is also fixedly provided with a junction box (8) for connecting an output line (83) in the motor shell; a cover plate (82) is fixedly arranged between the junction box (8) and the motor cavity, and the junction box (8) is sealed and isolated from the motor cavity by the cover plate (82);

and a cooling water channel is further arranged inside the side wall of the motor shell (4), and the cooling water channel is of one of a multi-ring type, a single-ring type or a spiral type structure.

2. The range extender structure with the motor cavity isolated from the terminal box cavity as claimed in claim 1, wherein the end cover (9) extends to the end of the terminal box (8) and is fixedly connected with the side wall of the terminal box (8), and the cover plate (82) is respectively connected with the outer side wall of the motor casing (4) and the inner side wall of the terminal box (8) in a sealing manner; the side wall of the motor shell (4) between the cover plate (82) and the end cover (9) is provided with a wiring through hole; the cover plate (82) is also provided with a sealing wiring hole.

3. The range extender structure with the motor cavity isolated from the terminal box cavity as claimed in claim 1, wherein one end of the motor casing (4) is fixedly connected with the engine (1) through a fixing bolt (3).

4. The range extender structure for isolating a motor cavity from a junction box cavity according to claim 1, wherein a compression ring (61) matched with the rotor assembly is fixedly arranged at the end part, close to the end cover (9), of the rotor support (5).

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