Research on the connection technology reliability of the range extender system

This paper analyzed the advantages and disadvantages of two common range extender system connection schemes in the market. In order to solve the problem of range extender which is prone to produce broken axis problems in the market, the elastic coupling connection scheme of range extender system is proposed. The structure composition and working principle of elastic coupling were expounded, and the reliability of elastic coupling was analyzed. According to the overall stress distribution map and overall deformation distribution map of the elastic coupling, the maximum stress of the motor spline shaft is 125 MPa, the maximum deformation is 17.4 um, and the strength and stiffness of the motor input shaft meet the reliability requirements of the range extender system.