Method of converting vehicle into hybrid vehicle

• US 8,596,391 B2
• Filed: 09/14/2010
• Issued: 12/03/2013
• Est. Priority Date: 09/15/2009
• Status: Expired due to Fees

• Current Assignee: KPIT Technologies Ltd.
• Original Assignee: KPIT Cummins Infosystems Limited
• Inventors: Kshatriya, Tejas Krishna
• Primary Examiner(s): TRINH, MINH N
• Application Number:
  US12/882,006
• Publication Number:
  US 20110083309A1
• Time in Patent Office: 1,176 Days
• Field of Search: 294/011, 294/020.8, 298/880.11, 180/65.22, 180/65.1, 474/84
• US Class Current: 180/65.22
• 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 11/06 with air cooling
• CPC Class Codes: B60K 2001/0416 Arrangement in the rear part of the vehicle
• CPC Class Codes: B60K 6/485 Motor-assist type
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2270/40 related to technical updates when adding new parts or software
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/15 Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 2050/146 Display means
• CPC Class Codes: B60W 2510/0638 Engine speed
• CPC Class Codes: B60W 2540/14 Clutch pedal position
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• 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: Y10T 29/49716 Converting

Abstract

A method of converting a vehicle having an internal combustion engine, a transmission, an alternator and a battery into a hybrid vehicle is disclosed. The method comprises installing an electric motor to the vehicle that is configured to assist the internal combustion engine in rotating a crankshaft of the internal combustion engine, installing an energy storage element configured to provide power to the electric motor, installing a motor control unit configured to control the amount of power delivered from the energy storage element to the electric motor and replacing an existing pulley on a crankshaft of the internal combustion engine with a new pulley configured to receive a first belt extending between the new pulley and an alternator pulley and a second belt extending between the new pulley and an electric motor pulley.

Claims

1. A method of converting a vehicle having an internal combustion engine, a transmission, an alternator and a battery into a hybrid vehicle, the method comprising:

installing an electric motor within the vehicle that is configured to assist the internal combustion engine in rotating a crankshaft of the internal combustion engine;

installing an energy storage element configured to provide power to the electric motor;

installing a motor control unit configured to control the amount of power delivered from the energy storage element to the electric motor; and

replacing an existing pulley on the crankshaft of the internal combustion engine with a new pulley configured to receive a first belt extending between the new pulley and an auxiliary motor pulley and a second belt extending between the new pulley and an electric motor pulley.

2. The method of claim 1 further comprising removing a manifold heat shield from the internal combustion engine and coupling a mounting bracket in the same location for supporting the electric motor.

3. The method of claim 2 wherein the mounting bracket includes one or more openings to promote air flow around the electric motor.

4. The method of claim 2 further comprising applying a heat shield between the mounting bracket and the electric motor.

5. The method of claim 1 further comprising installing a switch device configured to cut off a supply of fuel to the internal combustion engine based on a signal received from the motor control unit.

6. The method of claim 1 further comprising installing a switch device under a clutch pedal of the vehicle that causes the electric motor to crank the internal combustion engine when activated.

7. The method of claim 1 further comprising installing a plug-in charger within the vehicle that allows a user to charge the energy storage element when the vehicle is not in use.

8. The method of claim 1 wherein the auxiliary motor pulley comprises an alternator pulley.

9. A method of converting a vehicle having an internal combustion engine and a transmission into a hybrid vehicle, the method comprising:

installing an electric motor within the vehicle that is configured to assist the internal combustion engine in rotating a crankshaft of the internal combustion engine;

coupling an output shaft of the electric motor to an end of the crankshaft that is opposite the transmission via a universal coupling, wherein an end of the output shaft of the electric motor is positioned opposite the end of the crankshaft, and wherein the universal coupling is configured to compensate for misalignment between the output shaft of the electric motor and the crankshaft of the internal combustion engine;

installing an energy storage element configured to provide power to the electric motor; and

installing a motor control unit configured to control the amount of power delivered from the energy storage element to the electric motor.

10. The method of claim 9 wherein the step of coupling an output shaft of the electronic motor to an end of the crankshaft that is opposite the transmission via universal coupling comprises coupling the output shaft of the electric motor to a pulley rotatably coupled to the internal combustion engine.

11. The method of claim 9 further comprising connecting a belt between the pulley and at least one of a first auxiliary pulley and a second auxiliary pulley.

12. The method of claim 11 wherein the first auxiliary pulley comprises an alternator pulley and the second auxiliary pulley comprises a compressor pulley for an air conditioning system.

13. The method of claim 9 further comprising attaching one or more mounting brackets within the vehicle to at least partially support the electric motor.

14. The method of claim 13 further comprising supporting the electric motor at least partially by the vehicle body.

15. The method of claim 9 further comprising installing a switch device configured to cut off a supply of fuel to the internal combustion engine based on a signal received from the motor control unit.

16. The method of claim 9 further comprising installing a switch device under a clutch pedal of the vehicle that causes the electric motor to crank the internal combustion engine when activated.

17. The method of claim 9 further comprising installing a plug-in charger within the vehicle that allows a user to charge the energy storage element when the vehicle is not in use.

18. The method of claim 9 further comprising removing and eliminating a need for at least one of an existing battery and an alternator from the vehicle.