CA3044921A1 - Motor vehicle with unlimited autonomy & amp; zero pollution - Google Patents

Abstract

Device which enables any motor vehicle, or any other vehicle equipped with tyres, preferably without an inner tube, to produce, when said vehicle is moving, sufficient electric energy to ensure the autonomy thereof for: - Propulsion, - Supplying power to the vehicle accessories, - Keeping the battery unit thereof fully charged. This energy production does not require any type of filling, nor any electrical energy or other type of energy to be recharged. When the electric vehicle equipped with the device according to the invention described is moving, it emits no pollution. Zero atmospheric pollution due to the use thereof. To achieve this result, the device according to the invention utilises the energy produced by successive deformations of the part of the tyre contacting the ground, as soon as the wheels of the vehicle rotate. Previously, this energy was lost; the device implemented according to the invention recovers it and uses it.

Description

MOTOR VEHICLE WITH UNLIMITED AUTONOMY & AMP; ZERO POLLUTION
-1- Technical field of the Invention Device that allows all electric motor vehicles to produce energy during operation, which is required for:
Propulsion, Power to accessories, Full charging of battery pack.
With no filling or recharging required, no pollution produced due to its use.

- 2- Prior state of the art.
The electric car and its range.
The limited range of electric cars forms part of the main obstacle that remains to date; this limitation must be improved if such vehicles are to offer a viable alternative to the internal combustion engine.
Currently, the electrical energy consumed is embedded in the vehicle, stored in batteries. Range is limited due to the size and weight of the batteries. This is a major obstacle.
To resolve this issue, hybrid vehicles are offered; equipped with a combustion engine that drives a generator; the electricity produced improves the range of the vehicle.
The combustion engine may be powerful enough to allow the vehicle alone to meet its initial characteristics.
In this mode of operation, such vehicles pollute to the same extent as conventional combustion vehicles.
Other operational solutions exist to provide additional energy that can extend the range of electric vehicles.
Examples include:
Recovery of energy during braking.
Technology using the shock absorbers of the car to recover the energy received during compression cycles.

Tires that would convert heat and motion into electricity using thermoelectric and piezoelectric components.
Piezoelectric roads to turn traffic into electricity.
Arrays of piezoelectric micro-generators converting recovered mechanical energy into electrical energy.
The use of the electromechanical properties of monocrystals.
New batteries improving energy storage capacity.
A wide range of projects are currently being studied. Most are long term.
Hydrogen used as a source of electricity generation for fuel cells can provide a non-polluting fuel for the propulsion of electric cars.
The possibility of using hydrogen which, via a chemical reaction, produces electricity, is futuristic, although the fuel cell emits neither pollutants nor CO2 while driving, producing hydrogen requires a great amount of energy in upstream processes.

-3- Presentation of the invention.
Device which allows an electric motor vehicle, preferably equipped with tubeless tires, to produce, during operation, electrical energy sufficient to extend its range in terms of:
Propulsion, Power supply to accessories, Full charging of battery pack.
Requiring no replenishment of any kind To do this, the device used exploits the lost work produced by the successive deformations of the part of the tire in contact with the ground when the wheel rotates.
This work is characterized by the vertical displacement of the compressed section as well as the transmission of Fe forces produced. -- figure 1 page 1/7 The proposed device does not modify the value of the rolling coefficient of the tire considered, for a given load.
This lost work at each compression cycle is calculated according to the formula:
Work in joules = Fe in Nm X DV in m where . =

Fe = Value of the forces captured by the device installed, DV = vertical displacement corresponding to the height of compression in m Figure 2 page 1/7 The contact surface generated at each compression, multiplied by the air pressure in the tire, creates a set of forces that compensate for the weight supported by the wheels of the vehicle.
The exploitation of the work thus produced will allow, via an interposed mechanical device, to operate mini-generators.
The useful power output of each tire, for the needs of current motor vehicles, will be between 200 and 600 watts, it being specified that power produced for larger vehicles will be greater;
only the dimensions of these mini-generators will be increased according to the required characteristics.
The manufacture of such power grades at small sizes does not pose any specific problems for the manufacturers concerned.
We know that some power-assisted bikes use mini-generators delivering 250 watts of power, installed in the seat tube with a diameter of less than 40mm.
In an automobile car wheel, when the tire is installed, it is hermetically connected to the metal rim.
When inflated, the air is contained in a sealed volume, consisting of the interior of the tire and the part of the rim that faces it.
This single volume contains no other element except air or nitrogen, when inflated to the desired pressure.
To prevent the heat produced by the operation of the mini-generators and the corresponding mechanisms that will be installed therein causing malfunctions due to thermal exchange, the standard single volume is split, according to the invention described, into two independent compartments.
The first compartment corresponds to the volume of the air tire itself. The second compartment, below the first, is located in the upper part of the rim. It will house the mini-generators, their mechanisms, and all the sensors that will transmit useful information to the control software, thus ensuring the totality of the production of electrical energy required.
This compartment will house a mini-air compressor. According to its programming, it will maintain tire air pressure within the authorized limits by extracting or adding air.
Thermostat and hygrostat sensors installed in each compartment will send all the information to the program software which will respond according to the programmed instructions.

- = =

4 The compressor will provide forced ventilation when cooling conditions require it. Any temperature variations that may occur in the vicinity of the energy production unit must be considered to avoid condensation.
The capabilities of this compressor replace the so-called TPMS system required by European regulations since 2014.
The partition separating the two compartments will be composed of a light, rigid structure made of composite materials carbon fibers, fiberglass or other polymers of the polyacetals family.
This lightweight support, with form and dimensions suited to its function, will rest at its central section on the main chassis carrying the mini-generators and mechanisms; the lateral edges will rest on the inner edges of the rim.
This partition will serve as a support structure for a belt ring that will serve to delimit the air space within the tire. This will create a closed air volume identical to an air chamber consisting of two parts; the waterproof rubber of the so-called calendar tire, in the upper part, the belt ring at the lower part.
The installation of this ring will ensure airtightness between the two compartments.
Made of a soft, elastic, resistant butyl-type membrane or its equivalent, it will have at its center a number of holes corresponding to the number of mini-generators to be installed.
The diameter of these holes will be a few mm smaller than that of the cylindrical tubes carrying the 0-rings; these holes will be centered on these tubes; by pressing the membrane constituting the 0-ring, it will wrap around the cylinders indicated until resting on the partition already in place.
The central support surfaces and edges of the belt ring are to be adhesive, protected by a peelable silicone material. This will be removed during final installation to ensure airtightness between the two compartments.
The wheel of a car is made up of three main parts:
The tire envelope.
The rim.
The flange, its central part.
The entire assembly constitutes the wheel.
The contact area AC of the tread corresponds to the part of the tire which is, at instant t, in contact with the road, as the wheel rotates.
The tread, which is substantially equal to the outer circumference of the tire in question, when analyzed linearly, forms a succession of contact areas as the wheel rotates.
The length and width of each contact area depends on the characteristics of the tire installed on the vehicle, while their number, over a given period of time, depends on the linear speed of the wheel.
The surface area of each contact area varies according to three main characteristics:

The design features of the tire, in particular the stiffness of its sidewalls.
The recommended inflation pressure.
The weight of the vehicle plus the load carried.

5 Each compression cycle causes:
A height reduction, DV, the vertical distance between the inner rubber of the tire, calendar, and the part of the rim that faces it. DV corresponding to the difference in height between the outer radius Rext and the radius under load Rsch. Figure 2, page 1/7 A set of compression forces Fe.
A suitable device will recover and exploit the work produced at each compression cycle when the wheel turns; this lost work has been impossible to exploit to date.
The exploitation of these compression forces, as well as the displacement which results from it, will actuate the mini-generators fixed on the rim with suitable multiplier gearing. Figure 1, page The mechanical power of a force is the energy that is acquired or lost due to that force over a given time. Until now, the compression energy indicated above was lost.
For a given vehicle, the energy used for its propulsion, supply to its accessories, maintenance of its battery pack at full charge will be provided, according to the invention, by mini-generators installed on each wheel of the vehicle or on the number of wheels equipped with the device.
When the wheels of the motor vehicle turn, the motorization of the mini-generators is obtained by:
a The rotation of the racks propelled by Power Transmission Plates.
PTP
The PTP transmission plates are pushed, compressed by Fe compression forces produced by the deformation of the tire, with the creation of a contact area AC.
These reciprocating movements drive the mechanism of each multiplier housing, this mechanism driving the rotors of the corresponding mini-generators. Figure 1 page 7 / 7 The PTF returns to its top position by way of the simultaneous actions of springs with calibrated force and gravitational forces; a free wheel renders this displacement neutral.
Each compression cycle is characterized by two actions:
- Compression due to Fe compression forces, - Release due to the spring and gravitational forces.

6 The PTP force transmission plate transmits the movement to the rack that supports it; any other mechanical system, such as crank, cams and followers, may be used...
As soon as the calendar rubber of the tire at the compression area returns to its contact, the PTP
in question will follow the displacement imposed upon it.
To do this, the PTP is attached to the upper end of the corresponding rack drive rod via a connection to the ball joint which provides all the pivoting movements it is designed for, as well as the high forces and stresses produced.
The selected mechanism is regulated so that the PTPs never come into contact with the inner tire liner except when they become operational during compression cycles that occur as the wheel of the motor vehicle rotates.
Play in the order of 2 mm is provided and maintained between the calendar rubber and the upper part of the PTP, the inflation pressure being regulated in order to remain within the authorized limits in force.
On the other hand, through safety concerns and requirements for proper operation, each PTP is maintained at the height defined by four tethers, two on each side, in the direction of rotation of the wheel, which connect the left and right ends of the PTP to fixed anchors provided on the central tube carrying the 0-ring.
During each compression cycle, micro-friction may occur between the two surfaces in contact with the rubber of the calendaring and the materials constituting the upper part of the PTP. Due to their repetition and frequency, this contact can alter the reliability and durability of the components involved; to avoid this, the PTP is preferably to be made of titanium alloy, type alpha-beta or any other composite materials that can meet the requirements necessary for proper operation.
Deformation of the tire generates a contact area, AC. The sum of the vertical reactive forces in the contact area equals the applied load.
The changing form of the inner part of the tire that comes into contact with the top of the PTP
does not present a flat surface. Depending on the analysis and knowledge of the deformed part of the compression tire's structure, the top of the PTP is to be manufactured or cast in accordance with its form.
Tire manufacturers, considering their knowledge, experience and familiarity with tire technology, can, if they deem it necessary, strengthen the rubber in the calendar zone.
The installed device will prevent a situation where the gravitational forces experienced by the .. PTPs when the wheel rotates change the verticality of the rack drive rod.
If such a situation arose, the sealing of the 0-rings could over a long period of time become defective. In order to prevent this, four tethers identical to the previous ones will be used. They will connect two upper anchoring points on either side of the center of the PTP, in the direction of rotation of the wheel, at two fixed anchoring points on the central tube carrying the 0-ring.

7 These ropes to be of Liros D-Pro 01505 type, for example. As single braids with low dyncerna content, they are treated with polyurethane which gives them excellent resistance to abrasion;
with a diameter of 1.5 mm the breaking strength is greater than 200daN. Their ends are easy to braid and should be terminated with a spliced eye. This arrangement is simple to install, and no noise is emitted when subjected to repeated flexion.
Each PTP is to be connected to the central tube carrying the 0-ring with 8 tethers in total. When the PTP is in the low position, as commanded by the device program, the 8 folded tethers will be maintained in their correct position under the PTP by the action of the above-mentioned elastic ring.
If the motor vehicle studied is a four-wheeled vehicle for example, the area of each AC contact area will support a quarter of the weight of the vehicle plus the weight of the loads transported.
By design, the PTP top surface will be smaller than the tire/ground contact area. The maximum dimensions of the PTP in the direction of rotation of the wheel depends on the linear value of the circumference where all the PTPs are located when they are in the low position, the rest position.
The resultant linear value/number of mini-generators to be installed indicates the maximum possible size of the PTP in the direction of rotation of the wheel.
The second dimension of PTPs depends only on the actual width of the tire.
The thrust experienced by each PTP is equal to the compression forces given the ratio of the PTP/tire ground contact area surfaces in contact is:
Fe transmission = compression Fe X Surface PTP/Surface area of tire/ground contact.
The PTPs are automatically positioned by the program, either in the service position, or in the low position, rest position.
- As soon as notification of a loss of inflation pressure is sent to the program which controls the assembly, all PTPs within the wheel concerned will immediately be placed and maintained in the low position.
- When changing tires, before removal of the wheel concerned, all PTPs are automatically placed and maintained in the down position.
- After stoppage of the car, according to the timing programmed by the manufacturer, all the PTPs of all the wheels of the vehicle are placed in the down position.

8 - Depending on the manufacturer's decisions, all other programming strategies can be accommodated. All operational or fault information is displayed on the vehicle's dashboard, in particular the level of production and consumption of electrical energy, as well as any mini-generator failure.
The number of mini-generators to be installed will depend on the total energy to be produced, their electrical and dimensional characteristics, as well as the number of wheels installed.
Taking into account all these variables it is possible to calculate:
- The height, DV, a function of the desired displacement of the rack.
- The surface of the tire/road contact area.
- Fe compression forces.
- Fe transmission forces.
- The potential power of each mini-generator.
- Their number.
- The size of the rim.
- The tire and its characteristics, the inflation pressure compatible with the displacement.
DV, displacement of the rack, tread width The mini-generators may produce energy, according to the manufacturer's choices, in the form of direct current or alternating current. Whichever is chosen, the management of the power supplied will be suitably and conventionally managed by converters, inverters and the like, according to known techniques.
4 - Presentation of various sketches.

Illustration of the deformation of the part of the tire in contact with the ground.
Designation:
From the AC contact area.

. =

9 Of the DV compression height.
Linear representation of a succession of contact areas.

Section along direction of rotation of the wheel to present part of the device.
Power transmission plates, PTP.
Drive rod rack carrying the PTP.
This single tube round rack drive rod passes through the 0-ring and then screws to the top of the rack.
The carrier chassis that combines:
The elements allowing the reciprocating action of the rack, slide, guide. The upper part of the frame is circular and includes the 0-ring.
The mini-generator on one of its sides, on the second side the displacement gearbox in the center of the chassis is the main pinion driven by the rack.
Representation of the two compartments, air volume and production unit.

Section facing the wheel.
The assembly consisting of the chassis and mechanisms of a wheel equipped with the invention is presented.
12 identical locations in the example chosen for 11 mini-generators and 1 compressor.
All PTPs are positioned in service, except the one in front of the contact area formed by the compression cycle that is active.
Representation of the separation of the two compartments by the butyl sealing ring or material with similar characteristics.

Section along direction of rotation of the wheel.

The total stroke of the rack is equal to that of the PTP which actuates it reduced by the clearance which is defined by the design of the inner rubber surface of the tire and the top of the PTP, i.e., the 2 mm indicated.
5 This stroke does not bring the retaining groove of the lower end of the rack to the extent of the lock pins. The main spring returns the rack, the reciprocating action can continue.
If the system is intentionally programmed in such a way that a PTP remains in the bottom center position, the action triggered causes this mini-generator to stop, and to immediately switch to

10 motor mode;
this action compresses the spring until the end groove of the rack passes in front of the locking pins, under the action of their own springs, penetrating into the circular groove thus blocking the rack in the bottom position.
The reciprocating action is interrupted. The PTP is stopped in the bottom position.
To release the generator, the program triggers the power supply of the solenoid coil, the pins retract, the TPF is now active.

This section facing the wheel represents the attachment of the frame on the flange portion of the rim.

This sectional view of the device represents one of the feasible possibilities of exploitation of the lost work produced at each compression. The main pinion driven by the reciprocating action of the rack is manufactured on a hollow shaft, which allows the rotor shaft of the mini-generator to cross it as drawn.
The main pinion shaft carries at its end the multiplier housing, a gear of 48 teeth mounted on a freewheel.
The 48-tooth gear drives a 12-tooth gear that, without further gearing, powers the mini-generator rotor shaft.
When the rack has a useful stroke of 16 teeth, the main 16-tooth pinion in the same module turns once, as well as the pinion of 48 teeth mounted on its axis.
The latter driving a 12-tooth pinion, the multiplication of movement gives a transmission ratio equal to 4.
The end of the mini-generator rotor shaft carries a flywheel which contributes to the regulation of its speed.

11 All parts used, ball bearings, bearings, gears, freewheels, slides, racks must provide a service life of 10,000 hours.
The gears will preferably be of the helical type, which provides a smoother and quieter transmission.
Closing the multiplier housing will ensure complete sealing to prevent oil leakage. The main gear lubrication brush must not dry, harden or deteriorate.

Section along the direction of rotation of the wheel with marks illustrating the main components.
- 5 - Detailed presentation of one possible production method.
To capture the Fe forces, the forces produced during each compression of the part of the tire in contact with the roadway, the range of mechanical solutions that may be implemented are numerous.
All must achieve the same goal:
That the vehicle in question produces and consumes its own energy:
Propulsion, Power supply to accessories.
Full charging of battery pack.
The invention described makes it possible to use a conventional low-range battery supplemented with high-density super-capacitors. These are responsible for recovering the kinetic energy of the car during deceleration or braking phases.
The very fast charging capacity of these super-capacitors makes it possible to recover all the energy thus produced, which cannot be done by traditional batteries. It forms a complementary energy supply, especially when the traffic is very dense with frequent stops and starts.
The weight and volume of the battery pack with these traditional components +
super-capacitors, remain low.
Characteristics used as an example of production and feasibility.
- Family car, weight with driver 1,600 Kg.
- Four 17-inch wheels, 11 mini-generators in each wheel.
- 225/45 R 17 tires inflated as recommended.
- ................................................................ AC contact area under load indicated at each compression of the tire. 252 cm2 - ................................................................ Contact area of the PTP considered 168 cm2 - ................................................................ PTP/AC
surface ratio 0.66 . =

12 - .................................................................. Distance DV obtained at each compression of the tire- 18 mm - .................................................................. Movement of the corresponding rack 16 mm - .................................................................. Initial diameter of the main gear driven by the rack- 16 mm - .................................................................. Fe forces on wheel 1,600/4 X 9.81 3,924 Nm - Spring stress forces 40 Kg to return rack 40kg X 9,81 = .. 392 Nm - .................................................................
Theoretical forces exploitable by a single PTP = (3,924 X 0.66) -392.=
2,198 Nm If the assumed output is 0.60, the work in joules for 1 compression cycle is equal to:
Fe in Nm X DV in m X 0.6 output = 2198 X 0.016 X 0.6 = 21.10 joules.
If there is one compression cycle per second while the vehicle wheel is turning, the theoretical power that can be exploited by PTP is 21.10 watts.
The analysis of the power must be thorough, an important point in this example relating to knowledge of the engine torque at the main pinion in the first stage.
Rack engaged with the main 16-tooth pinion, pitch diameter 16 mm.
Motor torque = Driving Fe X pinion radius = 2198 Nm X 0.008 = 17.58 Nm at main pinion If we then consider an overall efficiency of 0.80 for the entire multiplier device the available engine torque is equal to 17.58 X 0.8 = 15.17 Nm.
The transmission ratio between the main pinion and the mini-generator shaft being 4, the torque available at rated speed will be 15.17 /4 = 3.79 Nm;
To drive an efficient mini-generator of 370 watts at 3,000 rpm at rated speed, the useful torque required is:
Useful torque required = 370 /(3000 X 2Pi / 60) = 1.17 Nm Result:
The available engine torque is sufficient to properly drive the mini-generator considered.
When the motor vehicle, equipped with the device according to the invention described, starts, the electrical energy supplying its motor or motors comes from the battery pack that it carries.
The mini-generators will from that moment begin to produce electrical energy.
When the car accelerates to 7.2 km/hour.
The tread of the wheel installed is 2 m in length.

. ,

13 At 7,200 meters per hour, the wheel completes 1 turn per second.
A PTP will drive its rack over an active displacement of 16 mm.
The main rack pinion completes 1 turn.
The rotor of the mini-generator completes 4 revolutions/second or 240 RPM via the multiplier.
The mini-generator delivering 370 watts at 3000 Rev/Mn when it is 240 Rev/Mn the power delivered will be close to (240/3,000) X 370 = 29.6 Watts.
The four wheels being equipped, 44 PTP, and many mini-generators, the electric power supplied at the speed of 7.2 km/hour is 29.6 X 44 = 1,302 Watts.
For a speed of 72 km/hour the electric power delivered is 13,024 Watts.
For a speed of 90 km/hour the electric power delivered is 16,280 Watts.
This last power rating for the vehicle is sufficient to supply all of its needs up to a speed of more than 180 km/hour. It is possible, according to the technical characteristics of manufacturing mini-generators, to operate at much higher speeds by improving the ventilation, certain characteristics of the compressor, more efficient choices of some materials provisionally specified.
The production of energy beyond the nominal characteristics of the specified mini-generators can only be exceptional and of short duration. This energy regulation is done simply by controlling the movement of the ascent of the racks. When the speed of the vehicle exceeds the defined ranges, a reduced stroke of the racks immediately causes a decrease in the speed of rotation of the mini-generators according to the established program.
The rack is limited in its stroke up to the height chosen according to program instructions simply by blocking the slide at the rack, by way of a self-locking pressure pad controlled by an electromagnet according to the programming strategy desired.
The recovery and exploitation device described can also be used when the tires have an air tube, only the PTPs need to be changed in order to transmit their movement to the racks. A ring of calibrated tensioners surrounds the air chamber; when the tire is compressed, the ring only partially follows the horizontal deformation of the tire, moving towards the center of the rim compressing the inner tube to an extent equal to its stroke, the displacement DV, to transfer the reciprocating movement to the corresponding rack as described for tubeless tires.

Claims

Claims.
- 1 - Electric motor vehicle, whose wheels, equipped with standard tires and the device according to the invention which characterizes it, produce as they turn, due to the deformations of the part of the tire in contact with the ground, enough work to motorize standard mini-alternators installed therein.
- 2 - The quantity of energy produced by the device according to the car model studied, is characterized by the possibility of choosing among the many possible technical variables indicated in the description, those which provide for the continued range of the vehicle as required by the specifications of the client.
- 3 - This device is characterized by the installation inside the tire of power transmission plates, "PTP", positioned inside the air space of the tire, without contact with the inner area of the tire, called the tire calendar; this system does not modify the value of the coefficient of rotation of the tire considered for a given load.
- 4 - The upper face of the "PTP" power transmission plates is characterized by their shape which are designed to be identical to that of the inner part of the tire calendar area at the moment of its deformation due to its passage and pressure on the ground.
- 5 - The plates are fixed to their rack support rod by a ball joint which characterizes them and provides excellent mobility and equivalent motion with the deformed part of the tire which propels them at each compression cycle thus producing, due to the high ratio of surfaces in contact with the tire/plate, enough torque to power the mini-alternators installed.
- 6 - The operation of mini-alternators is characterized by the fact that the compression height of a standard tire is sufficient to drive the rotors of mini-alternators via the device of the invention.
- 7 - When the wheels of the vehicle turn, the device is characterized by the reciprocating motion of the racks propelled by the action of the FE forces towards the center of the wheel; return springs with calibrated force reverse their movement, which is rendered neutral by a freewheeling device.
- 8 - The device is characterized by its installation within two independent compartments, which are airtight; the first is the classic pressurized air section of a tire, which contains the fe force transmission plates; the second located under the first in the rim space contains the mini-alternators, racks, mechanism and compressor.
- 9 - The two compartments are separated, and are characterized by a light, rigid partition, on which rests a butyl ring belt, forming an airtight insulating membrane;

all the components selected are of very low thermal conductivity in order to stabilize the heat exchange insofar as possible.
- 10 - A single airtight connection allows, and characterizes the device, the passage through an 0-ring of the reciprocating rack control rod between the two compartments for the transmission of motorization forces recovered by the plates.
- 11 - Device constituted of and characterized by four flexible tethers which maintain the plates at the required height, four other tethers identical to the previous ones ensure their verticality, in spite of the gravitational forces which they undergo.
- 12 - An air compressor installed in the mini-alternator compartment has as its function, and is characterized by, the maintenance of the air pressures and temperatures of the air compartment, by extraction or ventilation, according to the information transmitted to the program, by the pressure sensors, thermostats and hygrostats provided for this purpose.
-13- This compressor satisfies, and is characterized by compliance with, legislation pertaining to European regulations in force since 2004, and US regulations in force since 2007, that all the new vehicles must be equipped with a system called TPMS, which controls the pressure of the tires; the compressor is in any case required for the proper operation of the device.