CN222329457U

CN222329457U - Direct-connection range extender and hybrid electric vehicle

Info

Publication number: CN222329457U
Application number: CN202420957569.6U
Authority: CN
Inventors: 陈光明; 刘心允; 梁俊毅
Original assignee: Schaeffler Technologies AG and Co KG
Current assignee: Schaeffler Technologies AG and Co KG
Priority date: 2024-05-06
Filing date: 2024-05-06
Publication date: 2025-01-10
Anticipated expiration: 2034-05-06

Abstract

The embodiment of the utility model discloses a direct-connection range extender and a hybrid electric vehicle, wherein the direct-connection range extender comprises an engine, a generator and a rotor bracket, the engine comprises a crankshaft, the generator comprises a generator shell, the generator shell is provided with a centering shaft, the rotor bracket is in transmission connection with the crankshaft and is sleeved on the periphery of the centering shaft, one of the crankshaft and the centering shaft is provided with a positioning hole, the other one of the crankshaft and the centering shaft is provided with a positioning part, and the positioning hole is matched with the positioning part in a shape so as to embed the positioning part in the positioning hole. According to the utility model, the centering degree among the crankshaft, the generator shell and the rotor bracket is improved in the installation process, the precision requirement of installation equipment is reduced, and the installation difficulty of the generator on the engine is reduced.

Description

Direct-connection range extender and hybrid electric vehicle

Technical Field

The utility model relates to the technical field of hybrid electric vehicles, in particular to a direct-connection range extender and a hybrid electric vehicle.

Background

New energy electric vehicles are generated in face of increasingly severe energy situations and the tightening of automobile emission standards. And is limited by the capacity of a power battery, and the matching of the range extender is an effective means for solving the problem of the continuous voyage of the electric automobile. The range extender is used as an independent system added to the pure electric automobile, and is limited in weight and space. In order to solve the problem that the longitudinal dimension of the range extender is limited, a mode that a generator is arranged on an engine shell, and a generator rotor bracket is directly connected with an engine crankshaft is adopted.

In the installation process of installing the generator on the engine, the engine crankshaft, the rotor support and the generator shell are required to be centered, so that the rotor is installed at a proper position, and the phenomenon that the rotor on the rotor support is positioned poorly in the generator shell to rub against the stator in the electrode shell is avoided.

However, in the mounting process, the cylindrical positioning hole is difficult to accurately insert into the positioning hole on the engine crankshaft due to the overlarge tolerance, and further, the engine crankshaft, the rotor bracket and the shell are difficult to accurately center, so that the performance of the range extender is influenced.

Disclosure of utility model

The embodiment of the utility model provides a direct-connection range extender and a hybrid electric vehicle, which are used for improving the centering degree among a crankshaft, a generator shell and a rotor bracket in the installation process and reducing the installation difficulty of a generator on an engine.

In order to solve the technical problems, the embodiment of the utility model discloses the following technical scheme:

in one aspect, a direct-coupled range extender is provided, comprising:

An engine comprising a crankshaft (100);

A generator, comprising:

a generator housing having a centering shaft;

the rotor bracket is in transmission connection with the crankshaft and sleeved on the periphery of the centering shaft;

One of the crankshaft and the centering shaft is provided with a positioning hole, the other one is provided with a positioning part, and the positioning hole is matched with the positioning part in a shape so as to embed the positioning part in the positioning hole.

In addition to or in lieu of one or more of the features disclosed above, the locating hole is provided at an end of the crankshaft proximate the centering shaft;

The positioning portion is provided at an end portion of the centering shaft near the crankshaft direction.

In addition to or in lieu of one or more of the features disclosed above, the aperture of the locating hole gradually decreases in a direction away from the locating portion and the outer diameter of the locating portion gradually increases in a direction away from the locating hole.

In addition to or in lieu of one or more of the features disclosed above, the rotor support includes a continuous straight portion and a rotor mounting portion, the straight portion having a central bore therethrough along an axial direction thereof, the straight portion being received about an outer periphery of the centering shaft, the locating portion being received in the central bore.

In addition to or in lieu of one or more of the features disclosed above, the crankshaft has a boss at an end thereof adjacent the rotor support, the boss being embedded in a central bore of the direct connection.

In addition to, or in lieu of, one or more of the features disclosed above, further comprises:

and at least one spring washer is clamped between the crankshaft and the rotor bracket.

In addition to or alternatively to one or more of the features disclosed above, the spring washer includes at least one of an open spring washer, a wave spring washer, or a belleville spring washer.

In addition to or in lieu of one or more of the features disclosed above, the generator housing further comprises:

A centering cylinder coaxial with the crankshaft;

a side plate which is arranged around the periphery of the centering cylinder;

The end plate is arranged at one end of the side plate, which is away from the engine, and is connected with the side plate and the centering cylinder;

The connecting flange is arranged at one end of the side plate, which is close to the engine, and the side plate is fixedly connected with the engine through the connecting flange;

The side plates, the end plates, the connecting flanges and the centering cylinder enclose to form a containing cavity, the rotor support is at least partially contained in the containing cavity, and the centering shaft is arranged on one side of the centering cylinder, which faces the crankshaft.

In addition to or in lieu of one or more of the features disclosed above, the outer peripheral surface of the side plate is provided with a plurality of second mounting slots extending completely through the side plate in an axial direction;

a third fastener passes through the second mounting slot to fixedly mount the attachment flange to the engine.

In another aspect, a hybrid vehicle is further disclosed that includes a direct-connect range extender as described in any one of the above, in addition to or instead of one or more of the features disclosed above.

The technical scheme has the advantages that firstly, the positioning holes and the positioning parts which are matched with each other are arranged at the connecting positions of the crankshaft of the engine and the rotor bracket of the motor, and the connection between the generator and the engine can be completed without higher centering requirement in the installation process of the generator through the inclined plane matching between the positioning holes and the positioning parts, so that the precision requirement on installation equipment is reduced, the installation difficulty of the generator on the engine is reduced, and the manufacturing efficiency and reliability are improved. In the process of mounting the generator on the engine, the positioning portion enters the positioning hole along the depth direction column portion of the positioning hole, and the inclined inner peripheral surface of the positioning hole is abutted with the inclined outer peripheral surface of the positioning portion. The inclined inner peripheral surface and the inclined outer peripheral surface are mutually matched to have guiding effect and supporting effect, so that the centering degree among the crankshaft, the generator shell and the rotor bracket is improved, and the installation difficulty is further reduced. Secondly, the rotor support is sleeved on the periphery of the centering shaft, the rotor support is centered with the generator shell in the generator assembling process, double centering operation of the crankshaft, the generator shell and the rotor support in the generator mounting process in the prior art is avoided, mutual friction between the rotor on the rotor support and the stator on the generator shell caused by insufficient mounting is avoided, the mounting difficulty is further reduced, and the manufacturing efficiency and reliability are improved.

According to the application, the spring washer is arranged between the crankshaft and the rotor support, on one hand, the spring washer replaces a washer structure arranged according to the manufacturing tolerance of the crankshaft and the rotor support in the prior art, and the spring washer has the effects of reducing gaps between the crankshaft and the rotor support and improving the bonding degree of the crankshaft and the rotor support. On the other hand, the spring washer can also play a role in improving the assembling pretightening force between the crankshaft and the rotor bracket and improving the centering precision between the crankshaft and the rotor bracket.

Drawings

The technical solution and other advantageous effects of the present utility model will be made apparent by the following detailed description of the specific embodiments of the present utility model with reference to the accompanying drawings.

Fig. 1 is a schematic structural diagram of a direct-connection range extender according to an embodiment of the present utility model.

Fig. 2 is a cross-sectional view of a direct-coupled range extender provided according to an embodiment of the present utility model.

Fig. 3 is an exploded view of a direct-coupled range extender according to an embodiment of the present utility model.

Fig. 4 is a schematic diagram of an explosion structure of another view angle of a direct-coupled range extender according to an embodiment of the present utility model.

Fig. 5 is a schematic structural view of a rotor support in a direct-connection range extender according to an embodiment of the present utility model.

Fig. 6 is a schematic diagram of a crankshaft structure in a direct-coupled range extender according to an embodiment of the present utility model.

In the figure, 100-crank shaft, 101-positioning hole, 110-crank shaft main body, 120-connecting part, 1201-first end surface, 121-screw hole, 130-protruding part, 1301-second end surface, 200-generator shell, 201-containing cavity, 210-side plate, 220-centering cylinder, 221-guide hole, 230-connecting flange, 231-through area, 240-centering shaft, 241-positioning part, 250-end plate, 300-rotor bracket, 310-direct connection part, 311-center hole, 312-fixing hole, 320-rotor installation part and 400-spring washer.

Detailed Description

The utility model will be described in further detail below with reference to the drawings and detailed description. It should be understood that the detailed description is intended to illustrate the utility model, and not to limit the utility model.

Fig. 1 and fig. 2 show a schematic structural view and a cross-sectional view of a direct-connection range extender according to an embodiment of the present application. The direct-coupled range extender includes an engine including an engine housing (not shown) and a crankshaft 100 extending from the engine housing, and a generator mounted to the engine housing. The generator comprises a generator housing 200 and a rotor support 300, wherein the generator housing 200 is provided with a centering shaft 240, the rotor support 300 is at least partially accommodated in the generator housing 200, the rotor support 300 is sleeved on the periphery of the centering shaft 240, and the rotor support 300 is in transmission connection with the crankshaft 100.

Wherein, the end of the crankshaft 100 near the centering shaft 240 is provided with a positioning hole 101, the end of the centering shaft 240 near the crankshaft 100 is provided with a positioning part 241, the aperture of the positioning hole 101 gradually decreases along the direction far away from the centering shaft 240, so that the positioning hole 101 has an inner circumferential surface with gradually smaller inner diameter along the direction far away from the centering shaft 240, the outer diameter of the positioning part 241 gradually increases along the direction far away from the crankshaft 100, so that the positioning part 241 has a conical outer circumferential surface matched with the inner circumferential surface, the positioning part 241 is embedded in the positioning hole 101, and the inner circumferential surface of the positioning hole 101 is abutted with the outer circumferential surface of the positioning part 241.

The positioning part 241 is embedded in the positioning hole 101, and simultaneously, the centering of the crankshaft 100 and the centering shaft 240 is realized, and the centering of the crankshaft 100 and the rotor bracket 300 is synchronously realized due to the coaxial connection of the rotor bracket 300 and the centering shaft 240, so that the fixed connection of the crankshaft 100 and the rotor bracket 300 in the subsequent process is facilitated. When the engine outputs power, the crankshaft 100 drives the rotor bracket 300 to rotate, so that the generator works to generate electric power for driving the motor of the hybrid electric vehicle, and power transmission between the engine and the generator is realized.

The centering mode of matching the inclined inner peripheral surface and the inclined outer peripheral surface is adopted between the positioning hole 101 and the positioning part 241, so that on one hand, the production difficulty is reduced, the precision requirement on the installation equipment is reduced, the production cost is further reduced, the double centering in the installation process is avoided, the centering degree of the crankshaft 100, the rotor bracket 300 and the engine shell is improved, and the reliability of products is improved.

In the present embodiment, the positioning hole 101 is provided in the crankshaft 100, and the positioning portion 241 is provided in the centering shaft 240. In other embodiments, the positioning hole 101 may be disposed on the centering shaft 240, and the positioning portion 241 is disposed on the crankshaft 100, which is not specifically limited herein.

Fig. 3 and fig. 4 respectively show schematic explosion structures of a direct-connection range extender according to an embodiment of the application from different angles, and the generator housing 200 further includes a centering cylinder 220, a side plate 210, an end plate 250, and a connecting flange 230. The centering cylinder 220 has an open tubular structure, the centering cylinder 220 is coaxially disposed with the crankshaft 100, the opening of the centering shaft 240 faces away from the crankshaft 100, and the centering shaft 240 is disposed at an end of the centering cylinder 220 near the crankshaft 100 and fixedly connected with the centering cylinder 220. The side plate 210 has a cylindrical structure with openings at both ends, and the side plate 210 is sleeved on the outer periphery of the centering cylinder 220. An annular end plate 250 is provided at an end of the side plate 210 facing away from the crankshaft 100, the end plate 250 connecting the side plate 210 and the centering cylinder 220. The connecting flange 230 is disposed at an opening of the side plate 210 facing the crankshaft 100, and a plurality of uniformly distributed connecting holes 232 are axially disposed at an outer edge of the connecting flange 230. The connection holes 232 are used for fixedly connecting the connection flange 230 with the side plate 210 and fixedly connecting the connection flange 230 with the engine housing. A through region 231 penetrating through the thickness of the connection flange 230 is provided at the center thereof. The positioning portion 241 of the centering shaft 240 is fitted into the positioning hole 101 of the crankshaft 100 to achieve centering of the connection hole 232 of the connection flange 230 through the mounting hole thereof on the engine case. The centering cylinder 220, the side plates 210, the end plates 250 and the connecting flange 230 define a receiving cavity 201 inside the generator housing 200, and at least a part of the rotor support 300 and other components such as a stator and a rotor are received in the receiving cavity 201. Part of the rotor support 300 and the centering shaft 240 extend through the through region 231 of the connecting flange 230 to be connected with the crankshaft 100.

Specifically, the outer peripheral surface of the side plate 210 is provided with a plurality of first mounting grooves 2101 penetrating the side plate 210 in part in the axial direction and second mounting grooves 2102 penetrating the side plate completely, and the first mounting grooves 2101 and the second mounting grooves 2102 correspond to the connection holes 232 on the connection flange 230. The first mounting groove 2101 penetrates the side plate 210 at one end portion of the side plate 210 away from the connecting flange 230, a through hole penetrating the side plate 210 along the axial direction is formed in a portion of the side plate 210 corresponding to the first mounting groove 2101 in the axial direction, and a second fastener of a bolt structure penetrates the through hole and is screwed with the connecting hole 232 corresponding to the first mounting groove 2101, so that the connecting flange 230 and the side plate 210 are fixedly connected. The third fastening member of the bolt structure sequentially passes through the second installation groove 2102, the connection hole 232 and the installation hole on the engine housing to realize the fixed connection of the connection flange 230 and the engine housing, and further the generator is installed on the engine housing. The connection mode realizes the close fitting of the connecting flange 230 and the engine shell and the side plates 210 on two sides, and avoids the occurrence of the condition that gaps are formed between the connecting flange 230 and the side plates, thereby better realizing the centering among the crankshaft 100, the rotor bracket 300 and the generator shell 200 while the positioning part 241 is embedded in the positioning hole 101.

Fig. 5 shows a schematic structural diagram of a rotor support 300 in a direct-coupled range extender according to an embodiment of the present utility model, where the rotor support 300 includes a direct-coupled portion 310 and a rotor mounting portion 320. The center of the straight connecting portion 310 is provided with a center hole 311 penetrating along the axial direction thereof, so that the straight connecting portion 310 can be sleeved on the outer circumference of the centering shaft 240. A plurality of fixing holes 312 are provided around the circumference of the center hole 311, the fixing holes 312 penetrating the straight connecting portion 310 in the circumference of the straight connecting portion 310, the fixing holes 312 being fixedly connected to the crankshaft 100 by a first fastener. A plurality of guide holes 221 corresponding to the fixing holes 312 are provided on the centering cylinder 220 at positions corresponding to the fixing holes 312 one by one, so that the first fastening member can fixedly connect the rotor bracket 300 with the crankshaft 100 through the opening of the centering cylinder 220 and the guide holes 221 at a time after the centering shaft 240 is centered with the crankshaft 100. The rotor mounting portion 320 has a cylindrical structure, and the rotor mounting portion 320 is sleeved on the outer periphery of the centering cylinder 220 and connected to the direct connection portion 310. The rotor mounting part 320 is used for mounting the rotors, a plurality of rotors are mounted on the outer circumferential surface of the rotor mounting part 320, a plurality of stators are arranged on the inner side wall of the side plate 210 at positions corresponding to the rotor mounting part 320, and the stators are arranged opposite to the rotors, so that when the crankshaft 100 drives the rotor bracket 300 to rotate around the axis of the crankshaft, the magnetic fields of the stators and the rotors interact to generate electric power.

Fig. 6 shows a schematic structural diagram of a crankshaft 100 in a direct-coupled range extender according to an embodiment of the present utility model, where the crankshaft 100 includes a crankshaft main body 110, a connecting portion 120, and a protruding portion 130. The crank main body 110 has a roll-shaped structure. The connecting portion 120 has a disc-shaped structure, the connecting portion 120 is disposed at an end of the crankshaft main body 110, and an end surface of one side of the connecting portion 120, which faces away from the crankshaft main body 110, is a first end surface 1201. The protruding portion 130 is protruding on the first end surface 1201 of the connecting portion 120, and one side end surface of the protruding portion 130 facing away from the crankshaft main body 110 is a second end surface 1301, and the second end surface 1301 protrudes from the first end surface 1201. The positioning hole 101 is provided at the center of the boss 130. The end surface of the direct connection portion 310 facing the crankshaft is a third end surface 3101. The first end surface 1201 of the connection portion 120 abuts against the third end surface of the direct connection portion 310. Wherein, the outer diameter dimension of the positioning portion 241 is smaller than the diameter of the centering shaft 240, such that the end of the centering shaft 240 facing the crankshaft 100 has a fourth end surface 2401 surrounding the positioning portion 241, and the second end surface 1301 of the boss 130 abuts against the fourth end surface 2401 of the centering shaft 240. The positioning portion 241 is accommodated in the central hole 311, the inner diameter of the central hole 311 is matched with the outer diameter of the protruding portion 130, the protruding portion 130 is embedded in the central hole 311 of the direct connection portion 310, and the positioning portion 241 arranged on the fourth end face 2401 is embedded in the positioning hole 101 at the central position of the protruding portion 130. The staggered connection structure further improves the connection effect of the crankshaft 100 and the rotor bracket 300, and the centering degree among the crankshaft 100, the rotor bracket 300 and the centering shaft 240.

Further, a plurality of screw holes 121 corresponding to the fixing holes 312 of the rotor frame 300 are provided at the first end surface 1201 of the connection part 120 for the first fastening member to fixedly connect the crankshaft 100 and the rotor frame 300 through the fixing holes 312 and the screw holes 121, thereby achieving the transmission between the engine and the generator.

With continued reference to fig. 2 and 3, the direct-coupled range extender of the present application further includes a spring washer 400, the spring washer 400 being sandwiched between the crankshaft 100 and the rotor frame 300. Because the clearance is generated between the crankshaft 100 and the rotor due to the tolerance or thermal barrier contraction of materials, the spring washer 400 replaces a gasket structure arranged between the crankshaft 100 and the rotor support 300 according to the tolerance in the prior art, and the spring washer 400 has the functions of reducing the clearance between the crankshaft 100 and the rotor support 300 and improving the fit degree of the two. The spring washer 400 has an elastic force in the axial direction to improve the assembling pre-tightening force between the crankshaft 100 and the rotor bracket 300, thereby improving the connection effect of the crankshaft 100 and the rotor bracket 300 and improving the reliability of the product. In the process of installing the generator in the engine housing, the spring washer 400 also plays a role in absorbing the impact load of the rotor bracket 300 to the crankshaft 100 in the installation process, so that the damage of the rotor bracket 300 or the crankshaft 100 caused by collision in the installation is avoided, and the yield of products is improved.

In this embodiment, the spring washer 400 is a wave spring washer. In other embodiments, the spring washer 400 is a split spring washer or a belleville spring washer, and the like, and is not particularly limited herein.

In this embodiment, the spring washer 400 is sleeved on the outer periphery of the boss 130, and in the process of fastening and connecting the crankshaft 100 and the rotor support 300 through the first fastening piece, the spring washer 400 is gradually flattened until the crankshaft 100 and the rotor support 300 are attached through the spring washer 400. The process of gradually flattening the spring washer 400 under force is matched with the structure of the positioning hole 101 and the positioning part 241 with tapered cross sections, so that the crankshaft 100 and the rotor support 300 are further centered, the deviation displacement of the rotor support 300 relative to the crankshaft 100 caused by tolerance or other reasons after the generator is installed is compensated, and the centering precision between the rotor support 300 and the crankshaft 100 is further improved.

In another aspect, the present disclosure further discloses a hybrid vehicle, which includes the direct-coupled range extender described above, in addition to or instead of one or more of the features disclosed above, to provide driving power for traveling of the hybrid vehicle.

The above examples merely represent a few embodiments of the present application, and it should be noted that it is possible for a person skilled in the art to make several variations and modifications without departing from the scope of the present application. Accordingly, the scope of protection of the present application is to be determined by the appended claims.

Claims

1. A direct-coupled range extender, comprising:

An engine comprising a crankshaft (100);

A generator, comprising:

a generator housing (200) having a centering shaft (240);

a rotor bracket (300) which is in transmission connection with the crankshaft (100) and is sleeved on the periphery of the centering shaft (240);

One of the crankshaft (100) and the centering shaft (240) is provided with a positioning hole (101), the other one is provided with a positioning part (241), and the positioning hole (101) is matched with the positioning part (241) in a shape so as to embed the positioning part (241) in the positioning hole (101).

2. The direct-coupled range extender of claim 1, wherein the positioning hole (101) is provided at an end of the crankshaft (100) in a direction close to the centering shaft (240);

The positioning portion (241) is provided at an end of the centering shaft (240) in a direction close to the crankshaft (100).

3. The direct connection range extender according to claim 1 or 2, characterized in that the aperture of the positioning hole (101) gradually decreases in a direction away from the positioning portion (241), and the outer diameter of the positioning portion (241) gradually increases in a direction away from the positioning hole (101).

4. The direct-connection range extender of claim 1, wherein the rotor bracket (300) comprises a direct connection part (310) and a rotor mounting part (320) which are connected, the direct connection part (310) is provided with a central hole (311) penetrating along the axial direction of the direct connection part, the direct connection part (310) is sleeved on the periphery of the centering shaft (240), and the positioning part (241) is accommodated in the central hole (311).

5. The direct-coupled range extender of claim 4, wherein an end of the crankshaft (100) adjacent to the rotor bracket (300) has a boss (130), and the boss (130) is embedded in a central hole (311) of the direct-coupled portion (310).

6. The direct-connect range extender of claim 1, further comprising:

And a spring washer (400), wherein at least one spring washer (400) is sandwiched between the crankshaft (100) and the rotor bracket (300).

7. The direct connect range extender of claim 6, wherein said spring washer (400) comprises at least one of an open spring washer, a wave spring washer, or a belleville spring washer.

8. The direct connect range extender of claim 1, wherein the generator housing (200) further comprises:

a centering cylinder (220) coaxial with the crankshaft (100);

A side plate (210) which is provided around the outer periphery of the centering cylinder (220);

An end plate (250) disposed at an end of the side plate (210) facing away from the engine, the end plate (250) connecting the side plate (210) with the centering cylinder (220);

A connecting flange (230) arranged at one end of the side plate (210) close to the engine, wherein the side plate (210) is fixedly connected with the engine through the connecting flange (230);

Wherein, curb plate (210), end plate (250), flange (230) and centering cylinder (220) enclose and establish and form accommodation chamber (201), rotor support (300) at least partly hold in accommodation chamber (201), centering shaft (240) set up centering cylinder (220) towards one side of bent axle (100).

9. The direct-coupled range extender of claim 8, wherein the outer circumferential surface of the side plate (210) is provided with a plurality of second mounting grooves (2102) penetrating completely through the side plate (210) in the axial direction;

A third fastener passes through the second mounting slot (2102) to fixedly mount the attachment flange (230) to the engine.

10. A hybrid vehicle comprising a direct-coupled range extender as claimed in any one of claims 1 to 9.