Differential electric engine with variable torque conversion

• US 6,461,266 B1
• Filed: 04/26/2001
• Issued: 10/08/2002
• Est. Priority Date: 04/26/2001
• Status: Expired due to Term

• Current Assignee: CVET Patent Technologies Inc.
• Original Assignee: Ervin Weisz
• Inventors: Weisz, Ervin
• Primary Examiner(s): Marmor, Charles A
• Assistant Examiner(s): HO, HA DINH
• Application Number:
  US09/842,032
• Publication Number:
  US 20020160873A1
• Time in Patent Office: 530 Days
• Field of Search: 475/6, 475/5, 475/150, 475/151, 475/184, 475/221, 475/329, 475/332, 477/20, 477/15
• US Class Current: 475/5
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2220/42 with use of more than one motor
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/443 Torque
• CPC Class Codes: B60L 2240/486 Operating parameters
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 7/18 Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: F16H 2037/101 Power split variators with one differential at each end of the CVT
• CPC Class Codes: F16H 3/727 with at least two dynamo electric machines for creating an electric power path inside the gearing, e.g. using generator and motor for a variable power torque path special adapted for a hybrid electric vehicle B60K6/20
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 903/91 : Orbital, e.g. planetary gears

Abstract

The differential engine comprises a motor, a torque conversion stage, and a loading mechanism. The torque conversion stage includes first and second differential stages which are coupled together with a pair of shafts, with the shafts rotating in opposite directions. The first differential stage comprises an input shaft which is coupled to the output shaft of the motor, and first and second output shafts which are coupled to the respective shafts. The second differential stage comprises an output coupled to the output drive shaft, and first and second input shafts which are coupled to the respective shafts. The second differential stage includes a gear mechanism which applies a rotational torque to the output drive shaft when a difference occurs between the rotational speeds for the shafts. The rotational speeds of the shafts are varied by loading one or both of the shafts.

Claims

1. A differential engine with a variable torque output, said differential engine comprising:

(a) a motor for driving an output shaft at a rotational speed and applying an input rotational torque to said output shaft;

(b) a torque conversion stage coupled to said motor for converting said input rotational torque into a rotational torque at an output drive shaft for coupling to a load;

(c) said torque conversion stage including a first differential stage, said first differential stage having an input shaft coupled to the output shaft of said motor, and said first differential stage having a gear mechanism for translating the rotational torque from said input shaft to first and second output shafts and said gear mechanism driving each of said output shafts at the same speed and in opposing rotational directions;

(d) said torque conversion stage including a second differential stage, said second differential stage having a first input shaft coupled to the first output shaft of said first differential stage, and a second input shaft coupled to the second output shaft of said first differential stage, and including a gear mechanism for applying a rotational torque to said output drive shaft when a difference occurs between the rotational speeds of the first and second input shafts for the second differential stage;

(e) a loading mechanism, said loading mechanism being coupled to one of said input shafts on said second differential stage, said loading mechanism being responsive to a control input for loading said input shaft to vary the rotational speed of the associated input shaft.

2. The differential engine as claimed in claim 1, wherein said motor comprises an electric motor, and said electric motor includes a constant speed controller for operating the electric motor at a constant rotational speed in a predetermined direction.

3. The differential engine as claimed in claim 2, wherein said loading mechanism comprises an electric generator having a rotor, one end of said rotor being coupled to one of the output shafts of said first differential stage, and the other end of said rotor being coupled to one of the input shafts of said second differential stage, and said loading mechanism including a load capable of drawing a current from said electric generator in response to said control input.

4. The differential engine as claimed in claim 3, wherein said load comprises a battery charging circuit and a storage battery, said battery charging circuit being responsive to said control input for producing a regenerative charging current for charging said battery, and said battery being coupled to said electric motor for providing an energy storage device.

5. The differential engine as claimed in claim 4, further including a second electric generator having a rotor, one end of said rotor being coupled to the other output shaft of said first differential stage, and the other end of said rotor being coupled to the other input shaft of said second differential stage, and said generator generating an output in response to the rotational torque applied to said rotor by said other input shaft and said then output shaft.

6. The differential engine as claimed in claim 5, further including a second battery charging circuit, said second battery charging circuit having an input coupled to the output of said second generator and said second battery charging circuit being responsive to said control input for producing a regenerative charging current for charging said battery.

7. The differential engine as claimed in claim 3, wherein the output shafts of said first differential stage and the input shafts of said second differential stage are connected together, and the output and the input shafts include an embedded induction squirrel cage and form the rotor for the electric generator.

8. The differential engine as claimed in claim 3, wherein said load comprises a variable electric resistive load, said variable electric resistive load being responsive the control input for varying the load applied.

9. The differential engine as claimed in claim 3, wherein said load comprises an electrolytic chemical stage.

10. The differential engine as claimed in claim 1, wherein said loading mechanism comprises a mechanical braking device, said mechanical braking device being coupled to one of the input shafts in said second differential stage, and said mechanical braking device being responsive to the control input for varying the braking load applied to the input shaft.

11. The differential engine as claimed in claim 2, further including a drive mechanism, said drive mechanism being coupled to one of the input shafts on said second differential stage, said drive mechanism being responsive to a drive control input for rotating said one of input shafts at a variable rotational speed.

12. The differential engine as claimed in claim 11, wherein said loading mechanism comprises an electric generator having a rotor, one end of said rotor being coupled to the one of output shaft of said first differential stage, and the other end of said rotor being coupled to one of the input shaft of said second differential stage, and said electric generator including an output for coupling to a load capable of drawing a current from said electric generator in response to said control input.

13. The differential engine as claimed in claim 12, said drive mechanism comprises an electric motor having a rotor, one end of said rotor being coupled to one of the output shaft of said first differential stage, and the other end of said rotor being coupled to one of the input shaft of said second differential stage, and said electric motor including an input for coupling to the output of said electric generator and drawing a current from said electric generator in response to the drive control input.

14. The differential engine as claimed in claim 13, further including a controller for generating said control input and said drive control input, said controller having a generator driver coupled to said electric generator and being responsive to said control input for operating said electric generator to load one of said input shafts and said controller including a motor driver coupled to said electric motor and being responsive to said drive control input for operating said electric motor to rotate said other input shaft, and said controller including a speed sensor coupled to said output drive shaft for determining the rotational speed of said output drive shaft.

15. The differential engine as claimed in claim 14, wherein said controller further includes a network communication bus, said network communication bus providing an interface to another differential engine.

16. The differential engine as claimed in claim 14, wherein said controller further includes a torque sensor coupled to said output drive shaft for determining the rotational torque of said output drive shaft.

17. The differential engine as claimed in claim 2, further including an input stage and a second motor for driving an output motor shaft, said input stage having a first input shaft coupled to the output shaft of said first motor, and a second input shaft coupled to the output motor shaft of said second motor, and said input stage having an output shaft and said output shaft being coupled to the input shaft of said first differential stage, and said input stage including a gear mechanism for translating the rotational torque from said output motor shaft and said output shaft of said first motor to the output shaft of said input stage, and the output motor shaft for said second motor rotating in the same direction as the output shaft for the first motor.

18. The differential engine as claimed in claim 17, wherein said first motor comprises an electric motor and said second motor comprises a gasoline motor, and said electric motor includes a constant speed controller for operating the electric motor at a constant rotational speed in a predetermined direction.

19. The differential engine as claimed in claim 18, wherein said loading mechanism comprises an electric generator having a rotor, one end of said rotor being coupled to one of the output shaft of said first differential stage, and the other end of said rotor being coupled to one of the input shaft of said second differential stage, and said loading mechanism including a load capable of drawing a current from said electric generator in response to said control input.

20. The differential engine as claimed in claim 19, wherein said load comprises a battery charging circuit and a storage battery, said battery charging circuit being responsive to said control input for producing a regenerative charging current for charging said battery, and said battery being coupled to said electric motor for providing an energy storage device.

21. A differential engine with a variable torque output, said differential engine comprising:

(a) a motor for driving an output shaft at a constant speed in a predetermined direction;

(b) a transmission stage having an input shaft and an output drive shaft for driving a load, said input shaft being coupled to the output shaft of said motor;

(c) a regenerative charging stage, said regenerative charging stage having an input for receiving power from said transmission stage and charging an energy storage device;

(d) said transmission stage comprising a first differential stage and a second differential stage, said first differential stage having a drive mechanism coupled to said input shaft, and said second differential stage having a drive mechanism coupled to said output drive shaft, and the drive mechanism for said first differential stage being coupled to the drive mechanism for said second differential stage through first and second differential shafts, said differential shafts rotating in opposite directions at the same speed;

(e) said transmission stage including a generator coupled to one of said differential shafts, said generator being responsive to a control input for generating the power output for said regenerative charging stage, and operation of said generator loading said differential shaft and producing a difference in the speed of said differential shafts, and said drive mechanism in said second differential stage translating said difference to the rotational speed of said output drive shaft.

22. A differential engine with a variable torque output, said differential engine comprising:

(a) a first motor for driving an output shaft at a rotational speed and applying an input rotational torque to said output shaft;

(b) a second motor for driving an output motor shaft at a rotational speed and in a same direction as the output shaft for said first motor;

(c) a torque conversion stage coupled to said motor for converting said input rotational torque from said first motor and said second motor into a rotational torque at an output drive shaft for coupling to a load;

(d) said torque conversion stage including a first differential stage, said first differential stage having an input shaft, said first differential stage having a gear mechanism for translating the rotational torque from said input shaft to first and second output shafts and said gear mechanism driving each of said output shafts at the same speed and in opposing rotational directions;

(e) said torque conversion stage including a second differential stage, said second differential stage having a first input shaft coupled to the first output shaft of said first differential stage, and a second input shaft coupled to the second output shaft of said first differential stage, and including a gear mechanism for applying a rotational torque to said output drive shaft when a difference occurs between the rotational speeds of the first and second input shafts for the second differential stage;

(f) an input stage having a first input shaft coupled to the output shaft of said first motor, and a second input shaft coupled to the output motor shaft of said second motor, and said input stage having an output shaft and said output shaft being coupled to the input shaft of said first differential stage, and said input stage including a gear mechanism for translating the rotational torque from said output motor shaft and said output shaft of said first motor to the output shaft of said input stage;

(g) a loading mechanism, said loading mechanism being coupled to one of said input shafts on said second differential stage, said loading mechanism being responsive to a control input for loading said input shaft to vary the rotational speed of the associated input shaft.

23. The differential engine as claimed in claim 22, wherein said first motor comprises an electric motor and said second motor comprises a gasoline motor, and said electric motor includes a constant speed controller for operating the electric motor at a constant rotational speed in a predetermined direction.

24. The differential engine as claimed in claim 23, wherein said loading mechanism comprises an electric generator having a rotor, one end of said rotor being coupled to one of the output shafts of said first differential stage, and the other end of said rotor being coupled to one of the input shafts of said second differential stage, and said loading mechanism including a load capable of drawing a current from said electric generator in response to said control input.

25. The differential engine as claimed in claim 24, wherein said load comprises a battery charging circuit and a storage battery, said battery charging circuit being responsive to said control input for producing a regenerative charging current for charging said battery, and said battery being coupled to said electric motor for providing an energy storage device.