Powertrain, vehicle, and method with electric motors and dual belt drive

• US 8,276,693 B2
• Filed: 02/16/2011
• Issued: 10/02/2012
• Est. Priority Date: 02/16/2011
• Status: Expired due to Fees

• Current Assignee: American Challenge Technologies, Inc.
• Original Assignee: American Challenge Technologies, Inc.
• Inventors: Scarbo, Joseph N., Hartland, Derk, Wicks, Russel L., Hannemann, Neil E.
• Primary Examiner(s): Shriver, II, J. Allen
• Assistant Examiner(s): AVERY, BRIDGET D
• Application Number:
  US13/028,954
• Publication Number:
  US 20120052995A1
• Time in Patent Office: 594 Days
• Field of Search: 180/65.1, 180/65.21, 180/65.22, 180/65.31, 180/65.51, 180/65.6, 180/907, 474/86, 903/903
• US Class Current: 180/65.1
• CPC Class Codes: B60K 17/043 Transmission unit disposed in on near the vehicle wheel, or between the differential gear unit and the wheel
• CPC Class Codes: B60K 2007/0046 the motor moving together with the vehicle body, i.e. moving independently from the wheel axle
• CPC Class Codes: B60K 2007/0061 the motor axle being parallel to the wheel axle
• CPC Class Codes: B60K 7/0007 the motor being electric

Abstract

Electric vehicle powertrains, highway vehicles, and methods of manufacturing vehicles have dual belts driving wheels from two electric motors. Embodiments have a centrally-located transmission housing containing two belts and pulleys, and motors are mounted outside of the housing. A battery may power the motors and an internal combustion engine may power wheels on the other end of the vehicle through a separate transmission. Each belt may have a tensioner and drive shafts may have universal joints and decouplers. The transmission may have a central wall or supports which may support the pulleys and adjacent pulleys may have a common centerline and be supported by a common pin through the central wall.

Claims

1. An electric vehicle powertrain comprising:

a housing comprising a left wall and a right wall, the left wall having an inboard side facing the right wall and an outboard side facing away from the right wall, and the right wall having an inboard side facing the left wall and an outboard side facing away from the left wall, wherein the left wall and the right wall each have a motor shaft relief and a drive shaft relief;

a left electric motor mounted on the outboard side of the left wall at the motor shaft relief in the left wall and having a rotatable motor shaft;

a right electric motor mounted on the outboard side of the right wall at the motor shaft relief in the right wall and having a rotatable motor shaft;

a left drive pulley located on the inboard side of the left wall and rotatably attached to the rotatable motor shaft of the left motor through the motor shaft relief in the left wall;

a right drive pulley located on the inboard side of the right wall and rotatably attached to the rotatable motor shaft of the right motor through the motor shaft relief in the right wall;

a left driven pulley located on the inboard side of the left wall at the drive shaft relief in the left wall;

a right driven pulley located on the inboard side of the right wall at the drive shaft relief in the right wall;

a left drive shaft rotatably attached to the left driven pulley through the drive shaft relief in the left wall and extending away from the left wall on the outboard side of the left wall;

a right drive shaft rotatably attached to the right driven pulley through the drive shaft relief in the right wall and extending away from the right wall on the outboard side of the right wall;

a left drive belt on the inboard side of the left wall and extending around the left drive pulley and extending around the left driven pulley so as to rotatably connect the left drive pulley to the left driven pulley; and

a right drive belt on the inboard side of the right wall and extending around the right drive pulley and extending around the right driven pulley so as to rotatably connect the right drive pulley to the right driven pulley;

wherein;

the housing further comprises a central driven pulley support located between the left driven pulley and the right driven pulley;

the left driven pulley is supported from both the left wall and the central driven pulley support and

the right driven pulley is supported from both the right wall and the central driven pulley support.

2. The electric powertrain of claim 1 wherein:

the housing further comprises a central wall between the left wall and the right wall;

the central wall is between the left drive pulley and the right drive pulley;

the central wall is between the left driven pulley and the right driven pulley; and

the central wall is between the left drive belt and the right drive belt.

3. The electric powertrain of claim 1 further comprising:

a left side adjustable tensioner on the inboard side of the left wall that adjustably presses a tensioner pulley against the left drive belt between the left drive pulley and the left driven pulley; and

a right side adjustable tensioner on the inboard side of the right wall that adjustably presses a tensioner pulley against the right drive belt between the right drive pulley and the right driven pulley.

4. The electric powertrain of claim 1 further comprising multiple joining walls extending from the left side wall to the right side wall and holding the left side wall in rigid relation to the right side wall.

5. The electric powertrain of claim 1 wherein the left drive pulley and the right drive pulley have a common centerline and wherein the transmission housing further comprises a central drive pulley support located between the left drive pulley and the right drive pulley, wherein the central drive pulley support comprises a central drive pulley pin that extends to the left drive pulley and to the right drive pulley to support the left drive pulley and the right drive pulley.

6. The electric powertrain of claim 1 wherein the left driven pulley and the right driven pulley have a common centerline and wherein the central driven pulley support comprises a central driven pulley pin that extends to the left driven pulley and to the right driven pulley to support the left driven pulley and the right driven pulley.

7. The electric powertrain of claim 2 wherein the left drive pulley is supported from both the left wall and the central wall and the right drive pulley is supported from both the right wall and the central wall.

8. The electric powertrain of claim 2 wherein the left driven pulley is supported from both the left wall and the central wall and the right driven pulley is supported from both the right wall and the central wall.

9. The electric powertrain of claim 2 wherein the central wall is a flat plate.

10. The electric powertrain of claim 2 wherein the left wall, the right wall, and the central wall are all parallel to each other within five degrees.

11. A highway vehicle comprising:

a single, centrally-located transmission housing containing therein;

a left drive pulley;

a right drive pulley;

a left driven pulley;

a right driven pulley;

a left drive belt extending around the left drive pulley and extending around the left driven pulley so as to rotatably connect the left drive pulley to the left driven pulley; and

a right drive belt extending around the right drive pulley and extending around the right driven pulley so as to rotatably connect the right drive pulley to the right driven pulley;

a left electric motor rotatably attached to the left drive pulley;

a right electric motor rotatably attached to the right drive pulley;

a left drive shaft rotatably attached to the left driven pulley and extending outside of the transmission housing, wherein the left drive shaft comprises at least one universal joint outside of the transmission housing;

a right drive shaft rotatably attached to the right driven pulley and extending outside of the transmission housing, wherein the right drive shaft comprises at least one universal joint outside of the transmission housing;

a left wheel rotatably attached to the left drive shaft; and

a right wheel rotatably attached to the right drive shaft;

wherein;

the transmission housing further comprises a central wall;

the central wall is between the left drive pulley and the right drive pulley;

the left drive pulley is supported from the central wall; and

the right drive pulley is supported from the central wall.

12. The highway vehicle of claim 11 wherein:

the transmission housing has an outside surface;

the left electric motor is mounted on the outside surface of the transmission housing; and

the right electric motor is mounted on the outside surface of the transmission housing.

13. The highway vehicle of claim 11 wherein:

the left drive shaft comprises a left decoupler; and

the right drive shaft comprises a right decoupler.

14. The highway vehicle of claim 11 wherein the left wheel and the right wheel are a first wheel and a second wheel at a first end of the vehicle, and wherein the vehicle further comprises a third wheel and a fourth wheel at a second end of the vehicle and an internal combustion engine driving the third wheel and the fourth wheel.

15. The highway vehicle of claim 11 further comprising a battery powering the left electric motor and the right electric motor.

16. The highway vehicle of claim 11 further comprising a central drive pulley pin that extends to the left drive pulley and to the right drive pulley to support the left drive pulley and the right drive pulley.

17. The highway vehicle of claim 11 wherein:

the central wall is between the left driven pulley and the right driven pulley;

the central wall is between the left drive belt and the right drive belt;

the left driven pulley is supported from the central wall; and

the right driven pulley is supported from the central wall.

18. The highway vehicle of claim 11 further comprising:

a left side adjustable tensioner that adjustably presses a tensioner pulley against the left drive belt between the left drive pulley and the left driven pulley; and

a right side adjustable tensioner that adjustably presses a tensioner pulley against the right drive belt between the right drive pulley and the right driven pulley.

19. The highway vehicle of claim 11 further comprising a central driven pulley pin that extends to the left driven pulley and to the right driven pulley to support the left driven pulley and the right driven pulley wherein the left driven pulley and the right driven pulley have a common centerline.

20. A method of manufacturing a vehicle, the method comprising in any order at least the acts of:

manufacturing, obtaining, or providing an electric powertrain comprising;

a housing comprising a left wall and a right wall, the left wall having an inboard side facing the right wall and an outboard side facing away from the right wall, and the right wall having an inboard side facing the left wall and an outboard side facing away from the left wall, wherein the left wall and the right wall each have a motor shaft hole and a drive shaft hole;

a left electric motor mounted on the outboard side of the left wall at the motor shaft hole in the left wall and having a rotatable motor shaft;

a right electric motor mounted on the outboard side of the right wall at the motor shaft hole in the right wall and having a rotatable motor shaft;

a left drive pulley located on the inboard side of the left wall and rotatably attached to the rotatable motor shaft of the left motor through the motor shaft hole in the left wall;

a right drive pulley located on the inboard side of the right wall and rotatably attached to the rotatable motor shaft of the right motor through the motor shaft hole in the right wall;

a left driven pulley located on the inboard side of the left wall at the drive shaft hole in the left wall;

a right driven pulley located on the inboard side of the right wall at the drive shaft hole in the right wall, wherein the left driven pulley and the right driven pulley have a common centerline;

a left drive shaft rotatably attached to the left driven pulley through the drive shaft hole in the left wall and extending away from the left wall on the outboard side of the left wall;

a right drive shaft rotatably attached to the right driven pulley through the drive shaft hole in the right wall and extending away from the right wall on the outboard side of the right wall;

a left drive belt on the inboard side of the left wall and extending around the left drive pulley and extending around the left driven pulley so as to rotatably connect the left drive pulley to the left driven pulley;

a right drive belt on the inboard side of the right wall and extending around the right drive pulley and extending around the right driven pulley so as to rotatably connect the right drive pulley to the right driven pulley;

a central wall between the left wall and the right wall wherein;

the central wall is between the left drive pulley and the right drive pulley;

the central wall is between the left driven pulley and the right driven pulley;

the central wall is between the left drive belt and the right drive belt;

the left driven pulley is supported from both the left wall and the central wall;

the right driven pulley is supported from both the right wall and the central wall;

a left side adjustable tensioner on the inboard side of the left wall that adjustably presses a tensioner pulley against the left drive belt between the left drive pulley and the left driven pulley;

a right side adjustable tensioner on the inboard side of the right wall that adjustably presses a tensioner pulley against the right drive belt between the right drive pulley and the right driven pulley; and

multiple joining walls extending from the left side wall to the right side wall and holding the left side wall in rigid relation to the right side wall;

manufacturing, obtaining, or providing two universal joints in the left drive shaft and two universal joints in the right drive shaft;

manufacturing, obtaining, or providing;

a left first wheel rotatably attached to the left drive shaft at a first end of the vehicle;

a right second wheel rotatably attached to the right drive shaft at the first end of the vehicle;

a left third wheel at a second end of the vehicle; and

a right fourth wheel at the second end of the vehicle; and

manufacturing, obtaining, or providing a battery powering the left electric motor and the right electric motor.