Platforms for sustainable transportation

• US 7,017,690 B2
• Filed: 09/24/2001
• Issued: 03/28/2006
• Est. Priority Date: 09/25/2000
• Status: Expired due to Fees

• Current Assignee: Its Bus Incorporated
• Original Assignee: Its Bus Incorporated
• Inventors: Burke, Robert J.
• Primary Examiner(s): Dunn, David R.
• Application Number:
  US10/381,757
• Publication Number:
  US 20040012162A1
• Time in Patent Office: 1,646 Days
• Field of Search: 180/22, 180/23, 180/24, 180/24.02, 180/24.06, 180/24.07, 180/14.3, 180/234, 180/236, 180/65.3, 180/65.6, 280/5.5, 280/5.504, 280/5.514, 280/785, 280/91.1, 296/178, 296/193.04
• US Class Current: 180/24.07
• CPC Class Codes: B60G 2200/422 Driving wheels or live axles
• CPC Class Codes: B60G 2200/44 steerable
• CPC Class Codes: B60G 2202/152 Pneumatic spring
• CPC Class Codes: B60G 2206/011 Modular constructions
• CPC Class Codes: B60G 2206/0114 Independent suspensions on subframes
• CPC Class Codes: B60G 2300/14 Buses
• CPC Class Codes: B60G 2300/50 Electric vehicles; Hybrid vehicles
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 6/32 characterised by the fuel cells
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60K 7/0007 the motor being electric
• CPC Class Codes: B60Y 2200/143 Busses
• CPC Class Codes: B60Y 2200/1432 Low floor busses
• CPC Class Codes: B60Y 2200/91 Electric vehicles
• CPC Class Codes: B62D 29/04 predominantly of synthetic material working of plastics or substances in a plastic state B29
• CPC Class Codes: B62D 29/043 Superstructures B62D25/161 takes precedence
• CPC Class Codes: B62D 31/025 having modular sections
• CPC Class Codes: B62D 63/025 Modular vehicles superstructures for busses having modular sections B62D31/025
• CPC Class Codes: B62D 65/04 : Joining preassembled modular units composed of sub-units performing diverse functions, e.g. engine and bonnet B62D65/06 - B62D65/16 take precedence
• CPC Class Codes: B62D 7/1509 : with different steering modes, e.g. crab-steering, or steering specially adapted for reversing of the vehicle
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A vehicle utilize a cellular design to provide variously sized vehicles constructed from varying numbers of substantially identical cells. Each cell, fabricated from lightweight materials including composites, includes: compartment, floor section, sidewalls, roof, drive train, steering, brakes; and wheels coupled through axles and independent suspensions to the vehicle body, each suspension including a height adjuster, a flow-control shock absorber, and a rapid-response air spring for and exceptionally comfortable ride. The suspension system reduces structural requirements for the body. All-wheel steering lends the vehicle exceptionally high maneuverability. A hybrid power system combines an alternative fueled engine to power electricity generation and all-wheel electric drive with main energy storage in advanced battery technology. The cellular design and attendant weight reduction allow suspensions and drive trains to be substantially fabricated from light truck parts. A control system cooridnates and regulates the several sub-systems based on a variety of inputs.

Claims

1. A vehicle, said vehicle comprising:

at least two substantially identical cells, each cell having two ends and two opposing sides, a bottom surface and a top surface;

each cell comprising;

a body section;

at least one pair of wheels, one wheel on each of said opposing sides;

an axle for each wheel, said wheel coupled to said axle;

an independent, active suspension for each wheel, wherein said suspensions couple said axles to said bottom surface of said body section, said suspensions being microprocessor-controllable in response to operator input and roadway conditions;

a drive motor fixedly attached to said axle, wherein motive force is translated from said drive motor to said wheels;

wherein said cells are assembled end-to-end such that a rigid vehicle body structure is formed;

a steering system, wherein all of said wheels are operative to steer said vehicle, said steering system being microprocessor-controllable;

a power plant for generating power and supplying said power to said drive motors; and

one or more microprocessor control means for centrally controlling at least said suspensions and said steering system;

wherein providing multiple pairs of suspensions closely spaced reduces load requirements for said vehicle structure, so that suspensions for said transit vehicle are manufacturable from lightweight, stock parts.

2. A vehicle as in claim 1, said axle comprising one of:

an independent axle for each wheel; and

an end of a continuous axle having two opposing ends, said axle disposed such that said ends are at said opposing sides.

3. A vehicle as in claim 1, further comprising a front unit and an end unit, each of said front unit and said end unit being formed by modifying one of said cells.

4. A vehicle as in claim 1, said vehicle at least partially fabricated from lightweight materials.

5. A vehicle as in claim 4, wherein said lightweight materials include:

lightweight metal products; and

composite materials.

6. A vehicle as in claim 1, wherein said active suspension comprises:

a height adjuster;

an active air spring system;

an active shock absorber for damping motions of wheels under forces exerted by road surface contours and by said air spring system; and

a ride bumper, said ride bumper sitting between said body and said axle.

7. A vehicle as in claim 6, wherein said height adjustor comprises one of:

a system of mechanical guides and force applicators to effect vertical adjustment of each axle relative to the vehicle body; and

a system of mechanical guides and force applicators to effect independent vertical adjustment of each end of a continuous axle relative to the vehicle body.

8. A vehicle as in claim 7, wherein said height adjustor attaches said axle to an undersurface of said floor, so that said axle can move up and down when actuated by said system of mechanical guides and force applicators.

9. A vehicle as in claim 6, wherein a height adjustor is controlled independently of any other height adjuster.

10. A vehicle as in claim 6, said active air spring system comprising:

an air spring;

a plenum, said air spring in communication with said plenum;

a plurality of progressive fast acting valves disposed at intervals in said plenum, wherein total volume of air in said air spring system is varied by sequentially opening and closing said progressive valves.

11. A vehicle as in claim 10, wherein said valves comprise valve plates rotated by a common shaft at angular intervals.

12. A vehicle as in claim 10, wherein spring stiffness is inversely related to available system volume.

13. A vehicle as in claim 10, wherein force exerted by said spring system remains constant as stiffness varies.

14. A vehicle as in claim 6, said active shock absorber comprising:

a hydraulic fluid canister mounted to a top bearing plate of said spring;

a shaft having a first and second end, said first end attached to a lower bearing plate of said spring, said second end received by a central opening in a bottom face of said canister and wherein said shaft traverses a volume of said canister axially;

a valve stem, said valve stem emerging from a central opening in a top face of said canister, wherein said stem receives said second end of said shaft and surrounds said shaft concentrically;

a pusher plate, said pusher plate concentrically attached to said shaft such that said pusher plate is stationary and incapable of rotating;

a valve plate assembly, said valve plate assembly continuous with said valve stem, said valve plate assembly including at least two valve plates, said valve plates stationary with respect to each other, said valve plate assembly and said valve stem comprising a valve assembly;

wherein said pusher plate is sandwiched between said valve plates, and wherein said valve assembly rotates freely with respect to said pusher plate and said shaft.

15. A vehicle as in claim 14, wherein said valve plates and said pusher plate define a plurality of openings, and wherein openings in said valve plates are aligned with each other.

16. A vehicle as in claim 15, wherein alignment of valve plate openings with pusher plate openings is adjusted by rotating said valve assembly with respect to said pusher plate.

17. A vehicle as in claim 16, wherein fluid flow between compartments of said canister is regulated by setting alignment of said openings, and wherein said valve plates move through said fluid in piston-like fashion.

18. A vehicle as in claim 17, wherein obstructing fluid flow stoppers said shock absorber and prevents movement of said plates so that a maximum amount of damping is provided.

19. A vehicle as in claim 17, wherein degree of damping provided by said shock absorber is determined by alignment of openings.

20. A vehicle as in claim 17, further comprising an actuator, wherein said valve stem is connected to said actuator, and wherein said actuator rotates said valve stem to set alignment of said openings.

21. A vehicle as in claim 20, wherein said actuator is responsive to input from a control element.

22. A vehicle as in claim 14, wherein said shock absorber is operative to inhibit downward movement of said wheel.

23. A vehicle as in claim 1, said steering system comprising:

a steering control interface;

an all-wheel steering assembly; and

a steering actuator attached to each axle, wherein said axles are steerable in unison, or individually steerable.

24. A vehicle as in claim 23, said steering control interface including:

an operator interface; and

a control element, wherein said control element translates input from said operator interface to said steering actuators.

25. A vehicle as in claim 24, said operator interface comprising a steering column with steering wheel, said control element comprising a transducer, wherein said wheel is coupled to said transducer by means of a reduction gear.

26. A vehicle as in claim 24, wherein said operator interface comprising one of:

a joy stick; and

a computer pointing device.

27. A vehicle as in claim 24, wherein said steering system provides a plurality of all-wheel steering modes.

28. A vehicle as in claim 27, wherein said modes include;

conventional steering mode;

pivot mode;

crab mode; and

rail mode.

29. A vehicle as in claim 27, wherein an operator engages at least some of said modes by turning and manipulating said wheel with a minimum of additional control operations.

30. A vehicle as in claim 27, wherein an operator actuates a height adjuster system to raise and lower either side of said vehicle by manipulating said wheel.

31. A vehicle as in claim 24, wherein said control element is in communication with said steering actuators, and wherein control of individual axles is mediated by said steering actuators.

32. A vehicle as in claim 1, wherein said drive motor comprises one of:

a wheel motor, wherein an outer element rotates with a wheel and an inner element is fixed to an axle; and

a motor mounted to the vehicle inboard of the wheel, wherein power is delivered to the wheel by means of at least one translating members.

33. A vehicle in claim 1, wherein said drive motor comprises a high-efficiency electric motor.

34. A vehicle as in claim 32, said drive motor and said power plant together comprising a drive system, said drive system further comprising at least one battery pack.

35. A vehicle as in claim 34, wherein said drive motor powers a pair of wheels on opposing sides of the vehicle, said drive motor system further comprising a differential, said differential allowing said motor to be run at an efficient speed while allowing different rotation speeds for wheels.

36. A vehicle as in claim 34, said drive motor further comprising a drive motor controller, said drive motor controller in communication with said power plant, said controller driven by control software, said controller further including diagnostic software.

37. A vehicle as in claim 34, said translating member comprising a drive shaft, said drive shaft translating power to said wheels from said differential, said drive shaft comprising a shaft, a first end of said shaft communicating with said differential, a second end of said shaft communicating with a first side of a first CV joint, a half shaft communicating with a second side of said first CV joint, said half shaft connected to said wheel by means of a second CV joint.

38. A vehicle as in claim 34, said power plant comprising:

an engine, said engine serving as a basic power source for said vehicle;

a fuel tank;

a generator, wherein power from said engine is converted to electricity, said generator communicating with a drive shaft on said engine;

a generator controller to control capture of electricity and communicating with controllers on individual battery packs to coordinate charging of said battery packs;

an engine cooling system;

a hydraulic unit, said hydraulic unit providing hydraulic power to height adjustment, steering and braking systems;

a pneumatic unit, said pneumatic unit providing pneumatic power to at least said suspension;

an engine box; and

a climate control system for passenger areas.

39. A vehicle as in claim 38, wherein said engine comprises any of an internal combustion engine and a fuel cell engine.

40. A vehicle as in claim 38, wherein said engine utilizes for fuel one of:

gasoline;

diesel fuel;

propane;

natural gas; and

hydrogen.

41. A vehicle as in claim 34, said battery packs disposed in spaces of said vehicle body between each pair of wheels on opposing sides of the body, a battery pack including:

a battery pack housing;

a plurality of storage batteries contained within said housing;

at least one intake vent for cooling said batteries;

at least one output vent for venting exhaust gases from said batteries; and

at least one battery controller, said battery controller in communication with a generator controller.

42. A vehicle as in claim 1, further comprising a central control element, said control element operative to control and mediate operation and interaction of vehicle sub-systems and controllers.

43. A vehicle as in claim 1, wherein several vehicles are combined to form a train.

44. A suspension system for a multi-axle vehicle comprising:

a suspension for each wheel of said vehicle, a suspension comprising;

a height adjuster;

an active air spring system for maintaining body of said vehicle level relative to irregularities in a road surface;

an active shock absorber for damping forces exerted by said air spring system; and

a control element for independently controlling each of said suspensions in response to operator input and roadway conditions,

wherein said vehicle includes at least three evenly spaced pairs of wheels, one on each of opposing sides of the vehicle, each wheel mounted on an axle, said suspensions coupling said axles to an undersurface of said vehicle body, wherein providing said suspensions closely spaced reduces load requirements for structure of said vehicle.

45. A suspension as in claim 44, said axle comprising one of:

an independent axle for each wheel; and

an end of a continuous axle having two opposing ends, said axle disposed such that said ends are at said opposing sides.

46. A suspension as in claim 44, further comprising a ride bumper, said ride bumper sitting between the wheel body and an axle.

47. A suspension as in claim 44, wherein said height adjustor comprises one of:

a system of mechanical guides and force applicators to effect vertical adjustment of each axle relative to the vehicle body; and

a system of mechanical guides and force applicators to effect independent vertical adjustment of each end of a continuous axle relative to the vehicle body.

48. A suspension as in claim 47, wherein said height adjustor attaches said axle to an undersurface of said floor, so that said axle can move up and down when actuated by said system of mechanical guides and force applicators.

49. A suspension as in claim 47, wherein a height adjustor is controlled independently of any other height adjuster.

50. A suspension as in claim 44, said active air spring system comprising:

an air spring;

a plenum, said air spring in communication with said plenum;

a plurality of progressive fact acting valves disposed at intervals in said plenum, wherein total volume of air in said air spring system is varied by sequentially opening and closing said progressive valves.

51. A suspension as in claim 50, wherein said valves comprise valve plates rotated by a common shaft at angular intervals.

52. A suspension as in claim 50, wherein spring stiffness is inversely related to available system volume.

53. A suspension as in claim 50, wherein force exerted by said spring system remains constant as stiffness varies.

54. A suspension as in claim 44, said active shock absorber comprising:

a hydraulic fluid canister mounted to a top bearing plate of said spring;

a shaft having a first and second end, said first end attached to a lower bearing plate of said spring, said second end received by a central opening in a bottom face of said canister and wherein said shaft traverses a volume of said canister axially;

a valve stem, said valve stem emerging from a central opening in a top face of said canister, wherein said stem receives said second end of said shaft and surrounds said shaft concentrically;

a pusher plate, said pusher plate concentrically attached to said shaft such that said pusher plate is stationary and incapable of rotating;

a valve plate assembly, said valve plate assembly continuous with said valve stem, said valve plate assembly including at least two valve plates, said valve plates stationary with respect to each other, said valve plate assembly and said valve stem comprising a valve assembly;

wherein said pusher plate is sandwiched between said valve plates, and wherein said valve assembly rotates freely with respect to said pusher plate and said shaft.

55. A suspension as in claim 54, wherein said valve plates and said pusher plate define a plurality of openings, and wherein openings in said valve plates are aligned with each other.

56. A suspension as in claim 55, wherein alignment of valve plate openings with pusher plate openings is adjusted by rotating said valve assembly with respect to said pusher plate.

57. A suspension as in claim 56, wherein fluid flow between compartments of said canister is regulated by setting alignment of said openings, and wherein said valve plates move through said fluid in piston-like fashion.

58. A suspension as in claim 57, wherein obstructing fluid flow stoppers said shock absorber and prevents movement of said plates so that a maximum amount of damping is provided.

59. A suspension as in claim 57, wherein degree of damping provided by said shock absorber is determined by alignment of openings.

60. A suspension as in claim 57, further comprising an actuator, wherein said valve stem is connected to said actuator, and wherein said actuator rotates said valve stem to set alignment of said openings.

61. A suspension as in claim 60, wherein said actuator is responsive to input from a control element.

62. A suspension as in claim 54, wherein said shock absorber is operative to inhibit downward movement of said wheel.

63. A multi-axle vehicle, comprising:

a vehicle body;

at least three evenly spaced pairs of wheels, one on each of opposing sides of the vehicle, each wheel mounted on an axle;

a suspension provided for each wheel, said suspensions coupling said axles to an undersurface of said vehicle body, wherein providing said suspensions closely spaced reduces load requirements for structure of said vehicle, said suspension comprising;

a height adjuster;

an active air spring system for maintaining body of said vehicle level relative to irregularities in a road surface; and

an active shock absorber for damping forces exerted by said air spring system; and

a processor-mediated control element for independently controlling each of said suspensions in response to operator input and roadway conditions.

64. A vehicle as in claim 63, said axle comprising one of:

an independent axle for each wheel; and

an end of a continuous axle having two opposing ends, said axle disposed such that said ends are at said opposing sides.

65. A vehicle as in claim 63, further comprising a ride bumper, said ride bumper sitting between the wheel body and an axle.

66. A vehicle as in claim 63, wherein said height adjustor comprises one of:

a system of mechanical guides and force applicators to effect vertical adjustment of each axle relative to the vehicle body; and

a system of mechanical guides and force applicators to effect independent vertical adjustment of each end of a continuous axle relative to the vehicle body.

67. A vehicle as in claim 66, wherein said height adjustor attaches said axle to an undersurface of said floor, so that said axle can move up and down when actuated by said system of mechanical guides and force applicators.

68. A vehicle as in claim 66, wherein a height adjustor is controlled independently of any other height adjuster.

69. A vehicle as in claim 63, said active air spring system comprising:

an air spring;

a plenum, said air spring in communication with said plenum;

a plurality of progressive fast acting valves disposed at intervals in said plenum, wherein total volume of air in said air spring system is varied by sequentially opening and closing said progressive valves.

70. A vehicle as in claim 69, wherein said valves comprise valve plates rotated by a common shaft at angular intervals.

71. A vehicle as in claim 69, wherein spring stiffness is inversely related to available system volume.

72. A vehicle as in claim 69, wherein force exerted by said spring system remains constant as stiffness varies.

73. A vehicle as in claim 63, said active shock absorber comprising:

a hydraulic fluid canister mounted to a top bearing plate of said spring;

a shaft having a first and second end, said first end attached to a lower bearing plate of said spring, said second end received by a central opening in a bottom face of said canister and wherein said shaft traverses a volume of said canister axially;

a valve stem, said valve stem emerging from a central opening in a top face of said canister, wherein said stem receives said second end of said shaft and surrounds said shaft concentrically;

a pusher plate, said pusher plate concentrically attached to said shaft such that said pusher plate is stationary and incapable of rotating;

a valve plate assembly, said valve plate assembly continuous with said valve stem, said valve plate assembly including at least two valve plates, said valve plates stationary with respect to each other, said valve plate assembly and said valve stem comprising a valve assembly;

wherein said pusher plate is sandwiched between said valve plates, and wherein said valve assembly rotates freely with respect to said pusher plate and said shaft.

74. A vehicle as in claim 73, wherein said valve plates and said pusher plate define a plurality of openings, and wherein openings in said valve plates are aligned with each other.

75. A vehicle as in claim 74, wherein alignment of valve plate openings with pusher plate openings is adjusted by rotating said valve assembly with respect to said pusher plate.

76. A vehicle as in claim 75, wherein fluid flow between compartments of said canister is regulated by setting alignment of said openings, and wherein said valve plates move through said fluid in piston-like fashion.

77. A vehicle as in claim 76, wherein obstructing fluid flow stoppers said shock absorber and prevents movement of said plates so that a maximum amount of damping is provided.

78. A vehicle as in claim 76, wherein degree of damping provided by said shock absorber is determined by alignment of openings.

79. A vehicle as in claim 76, further comprising an actuator, wherein said valve stem is connected to said actuator, and wherein said actuator rotates said valve stem to set alignment of said openings.

80. A vehicle as in claim 79, wherein said actuator is responsive to input from a control element.

81. A vehicle as in claim 73, wherein said shock absorber is operative to inhibit downward movement of said wheel.