WO2013106049A1 - Châssis de véhicule à propulsion électrique - Google Patents

Châssis de véhicule à propulsion électrique Download PDF

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Publication number
WO2013106049A1
WO2013106049A1 PCT/US2012/032758 US2012032758W WO2013106049A1 WO 2013106049 A1 WO2013106049 A1 WO 2013106049A1 US 2012032758 W US2012032758 W US 2012032758W WO 2013106049 A1 WO2013106049 A1 WO 2013106049A1
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WO
WIPO (PCT)
Prior art keywords
energy storage
electric vehicle
vehicle platform
storage module
module
Prior art date
Application number
PCT/US2012/032758
Other languages
English (en)
Inventor
Seth SEABERG
Original Assignee
Trexa Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Trexa Llc filed Critical Trexa Llc
Publication of WO2013106049A1 publication Critical patent/WO2013106049A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/34—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles
    • B60K17/354—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles having separate mechanical assemblies for transmitting drive to the front or to the rear wheels or set of wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/34—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles
    • B60K17/356—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles having fluid or electric motor, for driving one or more wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/66—Arrangements of batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/02—Understructures, i.e. chassis frame on which a vehicle body may be mounted comprising longitudinally or transversely arranged frame members
    • B62D21/04—Understructures, i.e. chassis frame on which a vehicle body may be mounted comprising longitudinally or transversely arranged frame members single longitudinal type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/5825—Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K2001/001—Arrangement or mounting of electrical propulsion units one motor mounted on a propulsion axle for rotating right and left wheels of this axle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2410/00—Constructional features of vehicle sub-units
    • B60Y2410/10—Housings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

Definitions

  • the present invention generally relates to electric drive vehicles, unmanned vehicles and reconfigurable vehicles.
  • the electric drive vehicle chassis of the present invention addresses these market conditions and requirements.
  • This invention is a simplified electric drive vehicle chassis, referred to in this application as an "EDVC".
  • EDVC electric drive vehicle chassis
  • the first major assembly is an electricity storage system, referred to in this application as an "ESS”.
  • the second major assembly is an electric drive module, referred to in this application as an "EDM”.
  • the minor assembly in the EDVC is a suspension assembly, referred to in this application as the "SA”.
  • ESS serves as the energy storage mechanism as well as the principal structural, mechanical and electrical connection between two EDMs.
  • a primary aspect of this invention is the fact that the ESS serves as the main torsional, bending, and load bearing structure of the EVDC. This aspect reduces cost and complexity of an EVDC while having further benefits of providing a crashworthy location for an ESS as well as offering the greatest flexibility for construction of vehicular applications described in greater detail below.
  • VA vehicle chassis are permanently mated to a vehicular application, referred to in this application as a "VA", which can take the form of a conventional vehicle body, equipment, or other useful features attached to said vehicle chassis
  • this invention describes a number of VAs that might be suited to attachment to the EDVC, with said VAs being readily coupled to the EDVC.
  • some vehicle chassis are temporarily mated to a VA, in which cases the VA is typically equipment or other useful features attached to said vehicle chassis on a seasonal or otherwise conditional basis, this invention describes an ability to use the EDVC as a reconfigurable vehicle platform, or RVP, with said VAs being readily coupled to and decoupled from the EDVC.
  • RVP reconfigurable vehicle platform
  • Another primary aspect of this invention is the fact that both permanent and temporary VAs can be readily coupled to, and readily decoupled from, the EVDC.
  • the present invention describes the preferred embodiment of the ESS being a cylindrical shape with the main exterior insulating structure of the ESS being a non- conductive material with a nominally circular cross sectional geometry.
  • Another primary aspect of this invention is the fact that a carbon-fiber or other composite material insulating structure with intrinsic dielectric properties also has sufficient structural integrity to serve a dual purpose as the main torsional and load bearing structure of a vehicle chassis.
  • the present invention also represents an opportunity for physical scalability that until now has not been able to be implemented. Given that the more massive an electric drive vehicle, or the more massive its payload capacity, the larger its ESS capacity would need to be to provide sufficient driving range or operating time, and therefore the tube diameter and length can be scaled up accordingly. Further, vehicles of different sizes often require subtly different wheelbases, and therefore tube length can be scaled accordingly. Finally, given that the duty cycles of different vehicles vary with top speed and maximum torque requirements the more or less powerful the EDM needs to be, and therefore the EDM, being modular, can be scaled up or down accordingly.
  • a still further primary aspect of this invention is the fact that the ESS of the present invention provides virtually unlimited scalability at a low production cost and minimum of continued research and development.
  • the EDVC of the present invention can be a readily implemented platform for any vehicle including a small tactical robot, large earthmoving equipment and any wheeled or tracked vehicle in between.
  • FIGURE 1 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention.
  • FIGURE 2 is an enlarged isometric view of a cylindrical battery module in accord with an embodiment of the present invention.
  • FIGURE 3 is an enlarged isometric view of a cylindrical battery module in accord with an embodiment of the present invention.
  • FIGURE 4 is an isometric view of a cylindrical battery in accord with an embodiment of the present invention.
  • FIGURE 5 is an enlarged isometric view of a battery circuit routing module in accord with an embodiment of the present invention.
  • FIGURE 6 is another enlarged isometric view of a battery circuit routing module in accord with an embodiment of the present invention.
  • FIGURE 7 is an isometric view of a printed circuit board in accord with an embodiment of the present invention.
  • FIGURE 8 is an isometric view of a cylindrical battery pack in accord with an embodiment of the present invention.
  • FIGURE 9 is an isometric view of a cylindrical battery pack with an insulator in accord with an embodiment of the present invention.
  • FIGURE 10 is an enlarged isometric view of a mechanical structure for mechanically mating a cylindrical battery pack to another structure in accord with an embodiment of the present invention.
  • FIGURE 11 is another enlarged isometric view of a mechanical structure for mechanically mating a cylindrical battery pack to another structure in accord with an embodiment of the present invention.
  • FIGURE 12 is an isometric view of a cylindrical battery pack and mechanical mating structure in accord with an embodiment of the present invention.
  • FIGURE 13 is an enlarged isometric view of an electrical mechanism for electrically mating a cylindrical battery pack to another electrical mechanism in accord with an embodiment of the present invention.
  • FIGURE 14 is another enlarged isometric view of an electrical mechanism for electrically mating a cylindrical battery pack to another electrical mechanism in accord with an embodiment of the present invention.
  • FIGURE 15 is another enlarged isometric view of an electrical mechanism for electrically mating a cylindrical battery pack to another electrical mechanism in accord with an embodiment of the present invention.
  • FIGURE 16 is an isometric view of an energy storage system with requisite interfaces for utility in accord with an embodiment of the present invention.
  • FIGURE 17 is an enlarged isometric view of an electric drive module in accord with an embodiment of the present invention.
  • FIGURE 18 is another enlarged isometric view of an electric drive module in accord with an embodiment of the present invention.
  • FIGURE 19 is an isometric view of an energy storage system connected to two electric drive modules in accord with an embodiment of the present invention.
  • FIGURE 20 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention.
  • FIGURE 21 is an enlarged isometric view of an electric drive module integrated with a vehicle suspension in accord with an embodiment of the present invention.
  • FIGURE 22 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention with an embodiment of a vehicular application in accord with an embodiment of the present invention.
  • FIGURE 23 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention with an embodiment of a vehicular application in accord with an embodiment of the present invention.
  • FIGURE 24 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention.
  • FIGURE 25 is an isometric view of an embodiment of the electric drive vehicle chassis of the present invention with an embodiment of a vehicular application in accord with an embodiment of the present invention.
  • an electric drive vehicle chassis (EDVC) 1 is shown.
  • the EDVC 1 includes a front electric drive module (EDM) 3, a rear EDM 77, and a readily removable energy storage system (ESS) 2 connecting and providing torsional stiffness between the front EDM 3 and rear EDM 77.
  • EDM electric drive module
  • ESS readily removable energy storage system
  • the EDVC has a 96" wheelbase, is approximately 120" long overall, and weighs approximately 1,000 lbs.
  • the components can be proportionally increased or decreased in scale as desired or necessary for a particular application, to result in an EDVC 1 that is infinitely larger or smaller than the present embodiment of the invention.
  • FIGURES 2 AND 3 show a single battery module 5.
  • the battery module 5 includes a plurality of battery cells 24. In an embodiment, a total of eighteen battery cells 24 are included per battery module 5.
  • the battery cells 24 are arranged about an air plenum 85 with six internal cells disposed immediately about the longitudinal axis of the plenum 85, and twelve external cells disposed about the internal cells.
  • the battery cells 24 are preferably cylindrical lithium iron phosphate (LiFeP04) cells, but can be any suitable type of cell.
  • exposed electrical connections are covered by plastic insulators 20 and 21.
  • eighteen battery cells 24 are electrically configured into three groups of six cells.
  • a first group of six cells 24 is connected in parallel at the negative terminals of each cell by interconnect 70 to form a negative battery module 5 terminal 22.
  • the positive terminals of the first group of six cells 24 are connected to the negative terminals of a second group of six cells 24 by interconnect 68.
  • the positive terminals of the second group of six cells 24 are connected to the negative terminals of a third group of six cells 24 by interconnect 71.
  • the positive terminals of the third group of six cells 24 are connected by interconnect 67 to form a positive battery module 5 terminal 86.
  • a plurality of voltage pickup tabs 69 for connecting light wiring to battery management nodes are located on interconnects 68, 70, 71 and 72.
  • the number of cells 24 can be increased or decreased by adding or removing additional groups of cells 24 around the outside.
  • the module 5 capacity or voltage can be readily increased as desired or necessary for a particular application.
  • FIGURE 4 shows a battery 84 in accord with an embodiment of the invention.
  • a plurality of nominally cylindrical battery modules 5 is disposed along a common axis.
  • Positive bus bar 62 and negative bus bar 63 permit positive terminal 64 and negative terminal 53 of battery 84 to be extended to opposite ends of battery 84.
  • each group of six cells supplies 3.3 volts.
  • the entire battery module 5, therefore, supplies 9.9 volts using three separate voltages in series.
  • Battery pack 84 includes 10 battery modules 5, each supplying 9.9 volts, which connected in series supply 99 volts using thirty separate voltages in series.
  • ten battery modules 5 are connected in series within battery 84, and thus a total of 99 volts would be available. Assuming a capacity of 60 amp-hours, energy storage would be approximately 6 kilowatts. This is enough energy for a 96" wheelbase vehicle weighing 2,000 pounds to travel approximately 30 miles.
  • FIGURES 5 AND 6 show a battery circuit routing module (BCRM) 51.
  • the BCRM 51 includes a heavy-duty contactor (not shown), a 12-volt battery (not shown), a circuit board that converts serial communications to CAN messages (not shown) and electrical circuit routing (not shown) to permit, among other things, signal connections, auxiliary electrical connections and high voltage connections between the battery 84 and the electrical subsystems outside it.
  • FIGURE 5 shows the side of a BCRM 51 that is connected to battery 84. With a first BCRM 51 disposed at the negative end of battery 84, negative terminal 53 connects to main terminal receptacle 60, and with a second BCRM 51 disposed at the positive end of battery 84, positive terminal 64 connects to main terminal receptacle 60.
  • a serial communications signal from the battery management system node shown in FIGURE 7 is provided to both BCRMs 51 by connecting a fiber-optic wire (not shown) to fiber-optic wire receptacle 61. Also on both BCRMs 51, positive bus bar 62 shown in FIGURE 4 connects to positive bus bar receptacle 59, and negative bus bar 63 connects to negative bus bar receptacle 58.
  • FIGURE 5 shows the side of a BCRM 51 that comprises the outermost limit of the battery pack at either end. Each of the ports 55, 65, 56, and 57 are rendered electrically inert unless the heavy-duty contactor (not shown) inside the BCRM 51 is commanded closed by means of an external electrical signal provided through low voltage signal port 54.
  • FIGURE 7 shows a battery management node 52, which comprises a printed circuit board populated with commonly available micro-components (not shown).
  • BMS node 52 can monitor and balance six parallel cell group voltages, has independent logic and is independently powered by the voltages it is monitoring, so that battery 84 condition can be maintained without an external power source or command signal.
  • a plurality of BMS nodes 52 can be arranged in a series configuration using as many BMS nodes 52 are required to monitor an unlimited number of voltages.
  • FIGURE 8 shows a battery pack 4 comprising battery 84 integrated with the BMS nodes 52, and a first and second BCRM 51.
  • BCRMs 51 At the distal ends of the battery pack 4 are BCRMs 51 , with a first BCRM 51 connected to the positive terminal 64 (not shown) of battery 84 and with a second BCRM 51 connected to the negative terminal 53 of battery 84.
  • five BMS nodes 52 are disposed at equal intervals along battery pack 4, with each BMS node 52 located between two adjacent battery modules 5.
  • a first BMS node 52 monitors voltages 1 through 6, is serially connected via a pair of fiber-optic wires (not shown) to a second BMS node 52, which monitors voltages 7 through 12, and so on.
  • a fifth BMS node 52 in the series monitors voltages 25 through 30.
  • the fiber-optic wire series connection from a first BMS node 52 and a fifth BMS node 52 can terminate at either receptacle 61 on the first or second BCRM 51, which converts an aggregate of serial communications signals from the BMS nodes 52 to a CAN message for distribution to a vehicle control module (not shown).
  • the vehicle control module receives information about 30 voltages and processes this information accordingly.
  • FIGURE 9 shows the battery pack 4 insulated by tube 49.
  • a tube 49 contains and electrically insulates the plurality of cell modules 5.
  • the tube 49 is a hollow cylinder 9 inches in diameter, and is preferably made of carbon fiber or other lightweight dielectric composite tube.
  • the tube 49 is eighty inches long. This length will accommodate a ninety-six-inch wheelbase vehicle.
  • the wall of the tube 49 is approximately 1/4 inch thick. In other embodiments, the tube 49 can be increased or decreased in diameter and wall thickness as desired or necessary based on the intended application.
  • additional batteries 24 can be used to increase the voltage of each battery module 5 to 19.8 volts by doubling the number of batteries.
  • the 12-inch diameter tube 49 will also significantly increase the load- carrying capacity of the EVDC 1. Further, the tube 49 can be increased or decreased in length based on the intended application, thereby increasing or decreasing the wheelbase.
  • a 112-inch tube 49 is used, four additional modules 5 can be used to further increase the capacity of battery 84.
  • FIGURES 10 AND 11 show a mechanical interface assembly (MIA) 81.
  • a bonding surface 74 provides a means of permanently attaching, and in such a way as to be watertight, tube collar 42 to a corresponding collar bonding surface 73 on tube 49.
  • a collar locator 33 and a collar shoe 41 ensure tight fit with the corresponding mechanical interfaces on motor-transaxle 77.
  • FIGURE 12 shows the MIA 81 attached to the tube 49 at the bonding surface 74 and bonding surface 73.
  • FIGURES 13 AND 14 show an electrical interface assembly (EIA) 40.
  • EIA 40 electrical interface assembly
  • the side of EIA 40 that connects to BCRM 51 is with a means for electrically connecting electrical interface assembly 40 to BCRM 51 of battery pack 4.
  • Low voltage and signal connector 44 is connected to port 54 on BCRM 51.
  • Positive high voltage auxiliary connector 47 is connected to positive high voltage auxiliary port 55 on BCRM 51.
  • Negative high voltage auxiliary connector 48 is connected to negative high voltage auxiliary port 65.
  • a positive main battery terminal connector 46 is connected to positive battery terminal port 56 on BCRM 51.
  • a negative main battery terminal connector 45 is connected to negative battery terminal port 57 on BCRM 51.
  • a means of ducting air into battery pack 4 may be provided through the EIA 40 and further through BCRM 51 , but the entire ESS 2 must still be watertight by means of seal 87.
  • FIGURE 14 the side of EIA 40 that makes the final external electrical connections through positive main battery terminal mating pad 43, negative main battery terminal mating pad 38, and plug 39 is shown.
  • Positive battery terminal mating pad 43, negative battery terminal mating pad 38, positive high voltage auxiliary connector pin 88 and negative high voltage auxiliary connector pin 89 of plug 39 are rendered electrically inert unless the heavy-duty contactor (not shown) inside the BCRM 51 is commanded closed by means of an external electrical signal provided through low voltage signal pin 90 of plug 39.
  • FIGURE 15 the bottom of EIA 40 is shown.
  • Recess 91 is a means for ensuring a tight electrical connection between the positive battery terminal mating pad 43 and the corresponding positive connection 93 on EDM 77 as shown in FIGURE 17.
  • Recess 92 is a means for ensuring a tight electrical connection between the negative battery terminal mating pad 38 and the corresponding positive connection 93 on EDM 77 as also shown in FIGURE 17.
  • the principal aspects of BCRM 51 and EIA 40 are mechanically differentiated, but another embodiment may integrate BCRM 51 and EIA 40 into a single assembly and not depart significantly from the spirit of the invention.
  • FIGURE 16 shows the fully integrated ESS 2 comprising the battery pack 4, tube 49, MIA 81 and EIA 40.
  • ESS 2 now comprises a first, second, third and fourth mating fiange 34, a first and second mating shoe 41, a first and second positive battery terminal mating pad 43, a first and second negative battery terminal mating pad 38, and a first and second auxiliary electrical connection plug 39.
  • EIA 40 is sufficiently proximate to mechanical interface assembly 42 so that when ESS 2 interface mating flanges 34 are mechanically connected to EDM 77 mating flanges 13 and when ESS 2 mating shoes 41 are mechanically connected to EDM 77 mating foot 69, as shown in FIGURES 17-19, the EIA 40 becomes simultaneously electrically connected to EDM 77 through main battery terminals 43 and 48 and through low-voltage auxiliary electrical connection plug 39.
  • ESS 2 mating flanges 34 are secured to EDM 77 mating flanges 13 by means of hardware connecting through ESS 2 hardware holes 36 and EDM 77 hardware holes 15.
  • EDM 77 mating shoes 41 are secured to EDM 77 mating feet 96 by means of hardware connecting through ESS 2 hardware holes 37 and EDM 77 hardware holes 96.
  • the mechanical connection between EDM 77 and ESS 2 is located by, and further reinforced to withstand a plurality of axial loads by, an ESS 2 locating structure 33 nestling within an EDM 77 locating structure 97.
  • FIGURES 17 AND 18 show an electric drive module (EDM) 77.
  • EDM electric drive module
  • an electric motor 7 is connected perpendicular to the axle axis of transaxle 6, and by means of a gear reduction and differential assembly, not shown, power from the electric motor is transmitted to the axles at CV joint 9.
  • the motor-transaxle assembly 77 also comprises a linearly-actuated steering mechanism with an output 9 to a steering tie-rod, a mechanical interface for actuating the steering mechanism at input 17 to a steering column or an electric steering gear motor 25 as shown in FIGURE 21.
  • a control arm may be connected at outer control arm link 8 and inner control arm link 10.
  • a gas damper or coil-over-damper shock absorber may be connected at upper damper link 11.
  • a transverse leaf spring mount may be connected at leaf spring mounting holes 12.
  • EDM 77 In addition to transmitting power and supporting a suspension, as described above, EDM 77 also comprises a means of mechanically connecting motor transaxle 77 to ESS 2 using mating flanges 13 and mating foot 96. EDM 77 also comprises a means of
  • a vehicular application mating point (VAMP) 14 provides a hard point for a hardware connection to a vehicular application base frame 98 as shown in FIGURE 22.
  • VAMP 14 includes a through hole and a recess for a threaded fastener (not shown), so that when EDM 77 mating flange 13 is connected to ESS 2 mating flange 13, a captive nut is formed with sufficient movement in two axes so that attachment of unitized vehicular application base frames with low dimensional tolerances is readily achieved.
  • the throttle and regenerative braking of an electric drive system are enabled by electronic signals (rather than by mechanical actuation in a conventional vehicle).
  • the electric steering of EDM 77 is also enabled by an electronic signal. Each of these signals are communicated through plug 39.
  • FIGURE 19 shows an ESS 2 integrated with two EDMs 77.
  • FIGURE 20 shows an ESS 2 integrated with two EDMs 77 and two suspension assemblies 79 to form an EDVC 1 of the present invention.
  • the suspension assembly 79 includes a right hand suspension corner 50 and a left hand suspension corner 80, which in the preferred embodiment consist of identical sets of components.
  • CV joint 9 transmits power through axle 30 to wheel carrier 28.
  • a means of steering the wheels 99 is provided by steering tie rod 32.
  • Wheel carrier 28 is supported by control arm 29 at its lower link, and by transverse leaf spring 27 at its upper link.
  • Transverse leaf spring 27 is mounted to the motor-transaxle assembly 77 by means of a transverse leaf spring mount 31.
  • FIGURES 22 and 23 show an EDVC 1 integrated with a manned vehicular application 76.
  • a vehicle control module 100 is attached to the frame of application 76 and thereby interfaced with plug 39 when application 76 is attached to EVDC 1.
  • requests for throttle, brake and steering can be made from radio antenna 102 attached to manned vehicular application 76.
  • an unmanned vehicular application is shown in FIGURE 24 and 25.
  • vehicle control module 100 is interfaced with plug 39 when attached to EDM 77.
  • requests for throttle, brake and steering can be made from radio antenna 102 attached to unmanned vehicle control cockpit 103 that uses a video display 104 to provide tele-operation of EVDC 1 via vision sensor 103 other sensors (not shown).
  • vehicle control module 100 is interfaced with plug 39 when attached to EDM 77, and unmanned vehicle control cockpit 103 can be interchangeably attached or detached from EVDC 1 to provide manned or unmanned operation capability as a given application requires..

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Combustion & Propulsion (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Power Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)

Abstract

La présente invention se rapporte à un châssis de véhicule à propulsion électrique (EDVC pour Electric Drive Vehicle Chassis). Le châssis EDVC comprend un premier et un second module de propulsion électrique. Le châssis EDVC comprend également un système de stockage d'énergie (ESS pour Energy Storage System) raccordé aux premier et second modules de propulsion électrique, ainsi qu'une structure de torsion formant un seul bloc avec le système ESS. La plate-forme comprend en outre une interface d'application mécanique ; et une interface d'application électrique. Selon un autre aspect, la présente invention se rapporte à un châssis EDVC qui comprend un système ESS et une structure de torsion principale formant un seul bloc avec le système ESS. La plate-forme comprend également au moins un module de propulsion fixé au module de stockage d'énergie intégré et à la structure de torsion principale. Selon un autre aspect, la présente invention se rapporte à un châssis EDVC qui comprend un système ESS, un ou plusieurs modules de propulsion électrique et une structure de torsion principale formant un seul bloc avec le système ESS et des moyens permettant de fixer de manière interchangeable des applications de véhicule et leurs systèmes de commande pour permettre un fonctionnement avec conducteur humain et sans conducteur humain du châssis EDVC.
PCT/US2012/032758 2011-04-07 2012-04-09 Châssis de véhicule à propulsion électrique WO2013106049A1 (fr)

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JP2020093771A (ja) * 2018-12-11 2020-06-18 豊田合成株式会社 電動車両及びエネルギーパッケージ
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WO2015082201A1 (fr) * 2013-12-04 2015-06-11 Volkswagen Aktiengesellschaft Unité batterie et réseau de bord pourvu d'une unité batterie
FR3019382A1 (fr) * 2014-03-31 2015-10-02 Saft Groupe Sa Systeme mecanique de maintien pour maintenir une batterie dans un compartiment en forme de tube
EP2927992A1 (fr) * 2014-03-31 2015-10-07 Saft Groupe S.A. Systeme mecanique de maintien pour maintenir une batterie dans un compartiment en forme de tube
US10008701B2 (en) 2014-12-15 2018-06-26 A123 Systems, LLC Battery module system
WO2016100399A1 (fr) * 2014-12-15 2016-06-23 A123 Systems, LLC Système de module de batterie
WO2016193937A1 (fr) * 2015-06-03 2016-12-08 P-Gevs S.R.L. Voiture à traction électrique pouvant en particulier être utilisée comme taxi
EA037129B1 (ru) * 2015-07-15 2021-02-10 ДжиАй4 с.р.о. Шасси автомобиля с несущей центральной рамной трубой со встроенным вращающимся электродвигателем и применение
US10882558B2 (en) 2015-07-15 2021-01-05 Gi4 S.R.O. Arrangement of central load-carrying tube of motor vehicle chassis with integrated rotary electric motor, method of its placement and use
WO2017008770A1 (fr) * 2015-07-15 2017-01-19 Gi4 S.R.O. Agencement de tube de transport de charge centrale de châssis de véhicule automobile avec moteur électrique rotatif intégré, procédé de mise en place et utilisation de celui-ci
WO2018150007A1 (fr) * 2017-02-20 2018-08-23 Thyssenkrupp Ag Unité d'entraînement d'essieu, essieu moteur et véhicule à moteur
WO2018150009A1 (fr) * 2017-02-20 2018-08-23 Thyssenkrupp Ag Unité d'entraînement d'essieu dotée d'un système de direction, essieu moteur et véhicule à moteur
US11161399B2 (en) 2017-02-20 2021-11-02 Jheeco E-Drive Ag Axle drive unit comprising an inductive charging receiver, drive axle and motor vehicle
WO2018150008A1 (fr) * 2017-02-20 2018-08-23 Thyssenkrupp Ag Unité d'entraînement d'essieu dotée d'un système de freinage, essieu moteur et véhicule à moteur
US11117457B2 (en) 2017-02-20 2021-09-14 Jheeco E-Drive Ag Axle drive unit comprising a brake system, drive axle and motor vehicle
CN110300675A (zh) * 2017-02-20 2019-10-01 蒂森克虏伯股份公司 包括制动系统的车轴驱动单元、驱动车轴和机动车辆
WO2018220046A2 (fr) 2017-05-30 2018-12-06 Flet Gmbh Voiture électrique
WO2018220046A3 (fr) * 2017-05-30 2019-03-07 Flet Gmbh Voiture électrique
EP3409523A1 (fr) * 2017-05-30 2018-12-05 FLET GmbH Véhicule électrique
US11292325B2 (en) 2017-05-30 2022-04-05 Flet Gmbh Electric car
WO2020122091A1 (fr) * 2018-12-11 2020-06-18 豊田合成株式会社 Véhicule électrique et boîtier d'énergie
JP2020093771A (ja) * 2018-12-11 2020-06-18 豊田合成株式会社 電動車両及びエネルギーパッケージ
WO2021254847A1 (fr) * 2020-06-19 2021-12-23 Robert Bosch Gmbh Module de batterie, son procédé de fabrication et son utilisation
WO2021254848A1 (fr) * 2020-06-19 2021-12-23 Robert Bosch Gmbh Module de batterie, procédé de production et d'utilisation associés
CN113830175A (zh) * 2021-07-30 2021-12-24 浙江智莱科技有限公司 一种四轮越野无人线控车辆

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