BR202019007198U2 - kit to convert internal combustion engine vehicles to electric motor - Google Patents

Abstract

KIT TO CONVERT MOTOR VEHICLES TO INTERNAL COMBUSTION TO ELECTRIC MOTOR, where said kit consists of electrical and electronic components that will control an Electric Motor (Figure 1-3) to be fixed by screws on the Flange (Figure 1-2) which will be fixed to the vehicle transmission with screws. The system is started by an ignition key and a contactor that supplies the Controller, according to the electrical diagram (Figure 2). The rotation is activated by a Potentiometer (Figure 1-7) that is installed next to the accelerator pedal or handle. This is connected to the Controller (Figure 1-4) which is powered by a bank of Batteries (Figure 1-5), which are charged by a generator or charger (Figure 1-6). The Controller is a programmable electronic component that controls the motor speed and manages the acceleration ramp, like a frequency inverter. The kit also has a Panel (Figure 1-8) for information to the driver that indicates battery voltage, amperage, temperature and engine speed (RPM). It includes a Converter (Figure 1-9) for converting the battery voltage (which may vary according to the engine used) converting the voltage to 12V to supply the vehicle's original electrical controls (wiper, flashlights, radio, etc.). The battery pack (Figure 1-5) may or may not be supplied with the kit, which will be an optional item.

Description

KIT TO CONVERT ENGINE VEHICLES TO INTERNAL COMBUSTION TO ELECTRIC MOTOR TECHNICAL FIELD

[001] The following utility model patent descriptive report refers to the development of a KIT FOR CONVERTING INTERNAL COMBUSTION MOTOR VEHICLES to an ELECTRIC MOTOR, where the said kit consists of electrical and electronic components that will control an Electric Motor ( Figure 1-3) to be fixed using screws on the Flange (Figure 1-2) which will be fixed on the vehicle's Transmission (Figure 1-1). The system is started by an ignition key and a contactor that supplies the Controller, according to the electrical diagram (Figure 2). The rotation is activated by a Potentiometer (Figure 1-7) that is installed next to the accelerator pedal or handle. This is connected to the Controller (Figure 1-4) which is powered by a bank of Batteries (Figure 1-5), which are charged by a generator or charger (Figure 1-6). The Controller is a programmable electronic component that controls the motor speed and manages the acceleration ramp, like a frequency inverter. The kit also has a Panel (Figure 1-8) for information to the driver that indicates battery voltage, amperage, temperature and engine speed (RPM), among others. It includes a Converter (Figure 1-9) for converting the battery voltage (which may vary according to the engine used) converting the voltage to 12V to supply the vehicle's original electrical controls (wiper, flashlights, radio, etc.). The battery pack (Figure 1-5) may or may not be supplied with the kit, which will be an optional item. The kit is adaptable to any motor vehicle (car, motorcycle, truck, bus, etc.).

MOTIVATION

[002] Motor vehicles consist of an internal combustion engine - powered by fossil fuels and / or biomass (gasoline, diesel oil, natural gas, alcohol, biodiesel, flex, etc.) - coupled to the transmission in which the gear changes it can be automatic or manual. The transmission transfers torque to the wheel drive axle so that the vehicle can move. Combustion engines are sized according to weight, aerodynamics, as well as other physical and mechanical factors so that the vehicle reaches certain speeds and has sufficient power when going uphill.

[003] Despite the widespread use of this type of vehicle, mainly as a means of urban transport and use in general as utilities, this are the main emitters of greenhouse gases and toxic nitrogen gases. Also the high level of noise generated in urban centers. These engines require periodic maintenance - cleaning the carburetor and nozzles, changing the oil, changing the oil and air filters, timing belts, among others - generating a high cost for their owners.

[004] In view of the various problems and in order to overcome them, a Kit was developed composed of electronic and innovative parts to convert vehicles 100% into electric.

[005] The kit consists of removing the combustion engine - as well as its components (fuel tank, carburetor, radiator, etc.) - to install the electric kit, so that it will also lighten the vehicle's weight.

BACKGROUND

[006] US 20060000650 describes a kit for converting a vehicle with an internal combustion engine into a hybrid electric vehicle. The conversion kit is designed to increase fuel efficiency and, consequently, vehicle autonomy. Once converted, it will provide additional torque force over the original acceleration system. The System uses a new arrangement to intercept kinetic energy that would normally be wasted while the vehicle is decelerating or braking. The system converts kinetic energy into electrical energy to recharge the battery system - Source of electrical energy supply - for consumption when using the vehicle.

[007] A type of conversion kit can be seen in US 009308810, which serves to adapt an automotive vehicle from an electric motor coupled to a driving wheel to convert the combustion vehicle into a hybrid electric vehicle. The motor vehicle has at least one driving wheel mounted on the axle and the coaxial electric motor mounted on this axis to drive the driving wheel.

[008] Another important kit is described in PI0905101-5, which refers to a conversion kit for any automotive vehicles with an explosion engine and fossil fuels and / or biomass (like FLEX vehicles) such as Motorcycles, Cars, Utilities, Trucks, etc., simple and low cost, for pure electric vehicles with zero emission of pollutants and high autonomy and travel speeds, which can be installed in any mechanic and / or auto electric workshop, or leave the factory installed in new vehicles ( OKM), as the installation manual is an integral part of this kit, customized for each type of vehicle, which requires little, if any, maintenance in its later operation.

DIFFERENTIATION

[009] It is observed that the models currently available, have as main characteristic the hybrid conversion. In other words, new accessories are added, which in turn can be installed on the wheels or on the braking system, resulting in an increase in the vehicle's weight and not solving current problems. This is well described in the documents US 20060000650, US 009308810. This system of including other new components and not eliminating original components - such as the combustion engine and its components - implies that the vehicle will continue to have high maintenance costs, as well as replacement of periodically, oil, timing belt and other parts. Mainly, it will not extinguish the generation of pollutants from the gases generated by the internal combustion engine. In addition, adding more weight to the vehicle, it will focus on increasing fuel consumption and generating greater emission of polluting gases.

[010] The model described in document PI0905101-5, in spite of informing that it would be of low cost, is composed of parts with due particularities. To manufacture such a kit, a high investment would be necessary, estimated above R $ 60,000.00. The kit also consists of a Regenerative Brake: When the battery charge decreases, the gasoline engine immediately starts running, activating a generator that powers the electric motor and recharges the batteries. If the driver demands more from the car, the gasoline engine also participates in the wheel drive. As the author describes: "The secret lies in a complex set of electronic systems that manage, for example, the charge of the batteries, the operation of the gasoline engine and the brakes."

INNOVATION

[011] Thus, due to the pertinent considerations detailed in the previous topics, one of the objectives of the invention is the supply of a kit, in which the original parts of the vehicle (fuel tank, Filters, Radiator and others) will be removed for installation. they are components of the internal combustion engine, for conversion into a fully electric vehicle. The original parts removed may be resold on the market in order to help defray the investment in the electrical kit. The components to be applied are easy to purchase, most of which are market items commonly used in electric carts, forklifts, lifting platforms, among others. This way, the investment will be low and maintenance will not require a fully qualified technician. The main objective is to enable people with low purchasing power to also be able to have an electric vehicle, reducing their expenses and causing less negative impact on the environment.

[012] The battery pack (Figure 1-5) may or may not be supplied with the kit, they will be an optional item, as it will depend on the motor voltage and the autonomy required by the consumer. The batteries can be of the type Lead-acid Traction. Optionally, they can be lithium ion, nickel metal hydride, or any other technology that already exists, or that may exist in the future, as long as they are economically and technologically viable, providing the proper voltage for the correct operation of the engine. The choice will depend on the motor voltage and the range required by the consumer.

[013] The characterization of the present document for invention is made by means of drawings representative of the constructive disposition applied in a motor vehicle, in such a way that the equipment can be fully reproduced by an appropriate technique, allowing full characterization of the functionality of the object claimed.

[014] Based on the figures drawn up that express the preferential way of carrying out the installation of the kit to the vehicle, now idealized - the descriptive part of the report is based - through a detailed and consecutive enumeration, where it clarifies aspects that may remain implied by the representation adopted, in order to clearly determine the protection now sought.

• • Figura 3 - vista em perspectiva, componentes montados na transmissão;
• • Figura 3-1 - transmissão do veículo automotor;
• • Figura 3-2 - Motor Elétrico que poderá ser de corrente contínua (CC) onde sua comutação (troca de energia entre rotor e estator) pode ser através de escovas (escovado) ou sem escovas (brushless) ou um motor de corrente alternada (CA) cuja a velocidade é variada pela frequência. Também Motor Sepex (excitação separada) que é um outro tipo de corrente contínua (CC). Independente de qual seja o tipo de motor adotado, sua alimentação será proveniente de uma bateria. Atualmente, os principais fornecedores são: WEG, SCHABMULLER, Moya e Cezarino, JULI Motorenwerk, ABM, GE Motor entre outros;
• • Figura 3-3 - Flange para acoplamento do motor elétrico na transmissão de veículo. Peça personalizada de acordo com o tipo de veículo, modelo ou marca (Ford, VW, GM, Fiat, etc.);
• • Figura 3-4 - Controlador programável PMC propicia controle suave e contínuo de motores com excitação independente. Um sistema eletrônico que resulta em alta eficiência, operação silenciosa e perdas reduzidas no motor e na bateria. Principais fornecedores: Curtis, ZAPI do Brasil, entre outros;
• • Figura 3-5 - Base dissipadora de calor em alumínio, necessária para evitar o aquecimento do controlador unidos por pasta térmica, a fim de melhor transferência de calor. Também inclui coolers (Figura 6-12) para ventilar o conjunto;
• • Figura 3-6 - Chapa Suporte do conjunto do controlador;

[015] These figures are merely illustrative, and may vary, as long as they do not run away from what was initially claimed.

• • Figure 3 - perspective view, components mounted on the transmission;
• • Figure 3-1 - motor vehicle transmission;
• • Figure 3-2 - Electric motor that can be of direct current (DC) where its switching (energy exchange between rotor and stator) can be through brushes (brushed) or brushless (brushless) or an alternating current motor ( AC) whose speed is varied by frequency. Also Sepex motor (separate excitation) which is another type of direct current (DC). Regardless of the type of engine adopted, its power will come from a battery. Currently, the main suppliers are: WEG, SCHABMULLER, Moya and Cezarino, JULI Motorenwerk, ABM, GE Motor among others;
• • Figure 3-3 - Flange for coupling the electric motor to the vehicle transmission. Customized piece according to the type of vehicle, model or brand (Ford, VW, GM, Fiat, etc.);
• • Figure 3-4 - PMC programmable controller provides smooth and continuous control of motors with independent excitation. An electronic system that results in high efficiency, quiet operation and reduced engine and battery losses. Main suppliers: Curtis, ZAPI do Brasil, among others;
• • Figure 3-5 - Aluminum heat sink base, necessary to prevent the controller from heating together by thermal paste, in order to better transfer heat. It also includes coolers (Figure 6-12) to ventilate the set;
• • Figure 3-6 - Support plate of the controller set;

• • Figura 4 - vista explodida Conjunto do Flange;
• • Figura 4-1 - Flange para fixação na Transmissão, peça universal adaptada a qualquer tipo, marca ou modelo de veículo;
• • Figura 4-2 - Flange para fixação no Motor; peça universal adaptada a qualquer marca ou modelo de motor;
• • Figura 4-3 - Acoplamento, peça universal adaptável para união entre o eixo do motor e disco da embreagem do veículo;
• • Figura 4-4 - Rolamento;
• • Figura 4-5 - Anel espaçador do rolamento;
• • Figura 4-6 - Parafusos de união da Flanges.

[016] The kit, object of this order also includes the already mentioned Flange, which is a set of parts for fixing the engine on the vehicle's transmission. This set maintains the vehicle's current clutch, so that gear shifting is preserved as original.

• • Figure 4 - exploded view of the Flange Assembly;
• • Figure 4-1 - Flange for attachment to the Transmission, universal part adapted to any type, make or model of vehicle;
• • Figure 4-2 - Flange for attachment to the Motor; universal part adapted to any make or model of engine;
• • Figure 4-3 - Coupling, universal part adaptable for union between the motor shaft and the vehicle's clutch disc;
• • Figure 4-4 - Bearing;
• • Figure 4-5 - Bearing spacer ring;
• • Figure 4-6 - Flanges connection screws.

• • Figura 5 - montagem do flange na transmissão;
• • Figura 5-1 - transmissão original do veículo;
• • Figura 5-2 - motor elétrico;
• • Figura 5-3 - conjunto do Flange, conforme Figura 4;
• • Figura 5-4 - parafusos e porcas de fixação do Flange na transmissão.

[017] The assembly of the motor and flange assembly is illustrated in Figure 5, according to the components described below:

• • Figure 5 - mounting the flange on the transmission;
• • Figure 5-1 - original vehicle transmission;
• • Figure 5-2 - electric motor;
• • Figure 5-3 - Flange assembly, as shown in Figure 4;
• • Figure 5-4 - Flange fixing screws and nuts on the transmission.

• • Figura 6 - vista explodida;
• • Figura 6-1 - transmissão original do veículo;
• • Figura 6-2 - motor elétrico;
• • Figura 6-3 - conjunto do Flange, conforme Figura 4;
• • Figura 6-4 - Controlador programável;
• • Figura 6-5 - Base dissipadora de calor;
• • Figura 6-6- Chapa Suporte do conjunto do controlador;
• • Figura 6-7 - Disco de embreagem original do veículo;
• • Figura 6-8 - Acoplamento;
• • Figura 6-9 - Parafusos de fixação do Flange na transmissão;
• • Figura 6-10 - Porcas de fixação do Flange na transmissão;
• • Figura 6-11 - Proteção do Controlador;
• • Figura 6-12 - Cooler para resfriamento do Controlador;
• • Figura 6-13 - Parafuso de fixação do controlador e da placa dissipadora;
• • Figura 6-14 - Porca de fixação do controlador e da placa dissipadora.

[018] In order to facilitate the assembly of the set in the vehicle transmission, an explanatory manual with the step-by-step will be sent with the kit. These figures are merely illustrative and may present variations, as long as they do not run away from what was initially claimed.

• • Figure 6 - exploded view;
• • Figure 6-1 - original vehicle transmission;
• • Figure 6-2 - electric motor;
• • Figure 6-3 - Flange assembly, as shown in Figure 4;
• • Figure 6-4 - Programmable controller;
• • Figure 6-5 - Heatsink base;
• • Figure 6-6- Support plate of the controller set;
• • Figure 6-7 - Vehicle's original clutch disc;
• • Figure 6-8 - Coupling;
• • Figure 6-9 - Flange fixing screws on the transmission;
• • Figure 6-10 - Flange fixing nuts on the transmission;
• • Figure 6-11 - Controller Protection;
• • Figure 6-12 - Cooler for cooling the Controller;
• • Figure 6-13 - Screw fixing the controller and the heatsink plate;
• • Figure 6-14 - Fixing nut for the controller and the heatsink plate.

• • Figura 7 - Fabricação e montagem do Flange;
• • Figura 8 - Conjunto do Flange;
• • Figura 9 - Conjunto motor com flange e embreagem;
• • Figura 10 - Protótipo instalado.

[019] In addition to the illustrative figures, this document also contains photographs - as a demonstration - of the prototype elaborated, installed and tested in a VW VW Beetle 1972. It is possible to verify the manufacture and assembly of the set as described in this report.

• • Figure 7 - Flange manufacture and assembly;
• • Figure 8 - Flange Assembly;
• • Figure 9 - Motor assembly with flange and clutch;
• • Figure 10 - Prototype installed.

Claims (1)

“KIT TO CONVERT MOTOR VEHICLES TO INTERNAL COMBUSTION TO ELECTRIC MOTOR”, characterized by being a kit composed of electrical and electronic components that will control an Electric Motor (Figure 3-1) to be installed with a Flange (Figure 1-2) vehicle transmission (Figure 1-1). The rotation is activated by a Potentiometer (Figure 1-7) that is installed next to the accelerator pedal or handle, this is connected to the Controller (Figure 1-4) which is powered by a battery bank (Figure 1-5) , which are charged by a generator or charger (Figure 1-6). The Controller is a programmable electronic component, it controls the motor speed and manages the acceleration ramp, like a frequency inverter. The kit also has a Panel (Figure 1-8) for information to the driver that indicates battery voltage, amperage, temperature and engine speed and includes a Converter (Figure 1-9) for converting the battery voltage, which may vary according to the engine used, at 12V to supply the vehicle's original electrical controls (wiper, flashlights, radio, etc.); and may contain a universal Flange Assembly (figure 4) that is adaptable to any type of motor vehicle; the engine can be dimensioned according to the consumer's need. In which you can choose DC motors featuring high torque and moderate rotation, so that the vehicle reaches an average speed of 60 to 80km per hour. Ideal for getting around on an urban route, where you don't need a high speed. It can also achieve higher average speed by opting for AC motor with moderate torque and high speed; the set of Batteries (Figure 1-5) may or may not be supplied with the kit, it will be an optional item, as it will depend on the motor sizing, system voltage and the autonomy required by the consumer. Option 1 - Automotive batteries, known as lead-acid batteries, have the advantage of low cost and simple maintenance. Option 2- Traction acid-lead, normally have high resistance to corrosion, greater resistance to cycles and allows deep discharges. They have an average cost and are generally robust. Option 3 - LiPO Batteries or Lithium Polymer is a type that contains in its electrolytes lithium salts retained in a solid polymer such as polyethylene oxide instead of solvents making them adaptable to different formats and allowing high discharge rates. They are generally light, but costly. Option 4 - Lithium ion batteries, widely used in portable electronic equipment, despite having greater energy storage capacity than tractionary ones, we do not indicate due to safety risks, as they are easily corrupted, flammable and can even explode at high temperatures, especially when charging. In addition, it is possible to choose any other technology that already exists, or that may exist in the future, as long as they are economically and technologically viable; the kit features a 100% electric system, completely eliminating the internal combustion engine as well as all original vehicle parts (engine, fuel tank, filters, radiator, sails, carburetor, and others) that are relevant to the internal combustion engine . The original parts removed may be resold on the market in order to help defray the investment of the electric kit; most components are commercial items that are easily accessible on the national market, applied to industrial electrical machines (forklifts, pallet trucks, lifting platforms, etc.).

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