ONBOARD GENERATOR DRIVE SYSTEM FOR ELECTRIC VEHICLES

• US 20150210152A1
• Filed: 01/27/2015
• Published: 07/30/2015
• Est. Priority Date: 01/30/2014
• Status: Active Grant

• Current Assignee: Workhorse Group Inc.
• Original Assignee: AMP Electric Vehicles Inc. (Workhorse Group Inc.)
• Inventors: Burns, Stephen S., Wires, Donald L., Arkus, Alan J.
• Granted Patent: US 9,481,256 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60K 6/387 Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
• CPC Class Codes: B60K 6/44 Series-parallel type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 53/00 Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/946 Characterized by control of driveline clutch

Abstract

An electric vehicle utilizes an internal combustion engine to drive the vehicle'"'"'s main electric drive system in the regeneration mode and to charge the battery when the vehicle is stopped. The electric vehicle'"'"'s main drive controller and motor are used as the generator to recharge the battery when the vehicle is stopped via a clutch mechanism allowing the motor to act as a generator while the vehicle is at rest. As the vehicle proceeds throughout the drive cycle, the vehicle is powered by the electric motor from the battery. The battery is recharged to a specified state of charge when the vehicle is parked. The internal combustion engine only operates to charge the battery, and the electric motor is used to propel the vehicle.

Claims

1. An electric vehicle comprising:

a battery module;

an electric motor assembly coupled to the battery module and operable in a drive mode and in a generator mode;

at least one ground engaging driven wheel coupled to the electric motor assembly via a first drive shaft assembly;

a first clutch assembly associated with the first drive shaft assembly;

an internal combustion engine operably coupled to the electric motor assembly via a second drive shaft assembly;

a second clutch assembly associated with the second drive shaft assembly; and

a controller operable to engage the first clutch assembly and disengage the second clutch assembly when the electric motor is in the drive mode and to disengage the first clutch assembly and engage the second clutch assembly when the electric motor assembly is in the generator mode and the internal combustion engine is driving the second drive shaft assembly to thereby charge the batter module.

2. The electric vehicle of claim 1 further comprising:

a charger operably connected to the battery module by which the battery module may be charged by connection of the charger to a power source external to the electric vehicle.

3. The electric vehicle of claim 2 wherein the first and second clutch assemblies are each disengaged when the charger is charging the battery module via the power source external to the electric vehicle.

4. The electric vehicle of claim 1 wherein the internal combustion engine does not drive the at least one ground engaging driven wheel.

5. The electric vehicle of claim 1 further comprising at least one of:

a fuel tank for the internal combustion engine;

an auxiliary hydronic heating system;

a hydroboost brake system; and

an electric power steering pump.

6. The electric vehicle of claim 1 further comprising:

a pair of ground engaging driven wheels;

an axle extending between and to which the pair of ground engaging driven wheels is mounted; and

a differential assembly coupling the first drive shaft assembly to the axle.

7. An electric vehicle comprising:

a battery module;

an electric motor assembly coupled to the battery module and operable in a drive mode and in a generator mode;

a pair of ground engaging driven wheels coupled to the electric motor assembly via a first drive shaft assembly;

an axle extending between and to which the pair of ground engaging driven wheels is mounted;

a differential assembly coupling the first drive shaft assembly to the axle;

a first clutch assembly associated with the first drive shaft assembly;

an internal combustion engine operably coupled to the electric motor assembly via a second drive shaft assembly;

wherein the internal combustion engine does not drive the pair of ground engaging driven wheels;

a second clutch assembly associated with the second drive shaft assembly;

a controller operable to engage the first clutch assembly and disengage the second clutch assembly when the electric motor is in the drive mode and to disengage the first clutch assembly and engage the second clutch assembly when the electric motor assembly is in the generator mode and the internal combustion engine is driving the second drive shaft assembly to thereby charge the batter module; and

a charger operably connected to the battery module by which the battery module may be charged by connection of the charger to a power source external to the electric vehicle;

wherein the first and second clutch assemblies are each disengaged when the charger is charging the battery module via the power source external to the electric vehicle.

8. The electric vehicle of claim 7 further comprising at least one of:

a fuel tank for the internal combustion engine;

an auxiliary hydronic heating system;

a hydroboost brake system; and

an electric power steering pump.

9. A method of operating an electric vehicle having an electric motor assembly coupled via a first clutch assembly to at least one ground engaging wheel, an internal combustion engine coupled via a second clutch assembly to the electric motor assembly, a battery module electrically coupled to the electric motor assembly and a charger electrically coupled to the battery module, the method comprising the steps of:

configuring the electric vehicle for operation in a first state by,

(a) disengaging the first clutch assembly;

(b) disengaging the second clutch assembly; and

(c) coupling a power source external to the electric vehicle with the charger on the electric vehicle to thereby charge the battery.

10. The method of claim 9 further comprising:

configuring the electric vehicle for operation in a second state by,

(d) engaging the first clutch assembly;

(e) disengaging the second clutch assembly;

(f) drawing electric power from the battery module to the electric motor assembly; and

(g) operating the electric motor assembly in a drive mode to thereby drive the at least one ground engaging wheel to propel the electric vehicle.

11. The method of claim 10 further comprising:

configuring the electric vehicle for operation in a third state by,

(h) disengaging the first clutch assembly;

(i) engaging the second clutch assembly;

(j) operating the electric motor assembly in a generator mode; and

(k) operating the internal combustion engine to thereby charge the battery module via the electric motor assembly while in the generator mode.

12. The method of claim 11 wherein the operation of the electric vehicle in the third state is accomplished while the electric vehicle is stationary.

13. The method of claim 11 further comprising:

(l) calculating a desired state of charge for the battery module; and

(m) terminating operation of the electric vehicle in the third state once the battery module is at the desired state of charge.

14. The method of claim 10 wherein the internal combustion engine is not engaged to propel the at least one ground engaging wheel during operation of the electric vehicle in the second state.

15. A method of operating an electric vehicle having an electric motor assembly coupled via a first clutch assembly to a pair of ground engaging wheels, an internal combustion engine coupled via a second clutch assembly to the electric motor assembly, a battery module electrically coupled to the electric motor assembly and a charger electrically coupled to the battery module, the method comprising the steps of:

configuring the electric vehicle for operation in a first state by,

(a) disengaging the first clutch assembly;

(b) disengaging the second clutch assembly;

(c) coupling a power source external to the electric vehicle with the charger on the electric vehicle to thereby charge the battery;

configuring the electric vehicle for operation in a second state by,

(d) engaging the first clutch assembly;

(e) disengaging the second clutch assembly;

(f) drawing electric power from the battery module to the electric motor assembly;

(g) operating the electric motor assembly in a drive mode to thereby drive the at least one ground engaging wheel to propel the electric vehicle;

configuring the electric vehicle for operation in a third state by,

(h) disengaging the first clutch assembly;

(i) engaging the second clutch assembly;

(j) operating the electric motor assembly in a generator mode; and

(k) operating the internal combustion engine to thereby charge the battery module via the electric motor assembly while in the generator mode.

16. The method of claim 15 wherein the operation of the electric vehicle in the third state is accomplished while the electric vehicle is stationary.

17. The method of claim 15 further comprising:

(l) calculating a desired state of charge for the battery module; and

(m) terminating operation of the electric vehicle in the third state once the battery module is at the desired state of charge.

18. The method of claim 15 wherein the internal combustion engine is not engaged to propel the at least one ground engaging wheel during operation of the electric vehicle in the second state.