WO2022146239A1 - The method of converting over-life public transport vehicles into electric vehicles - Google Patents

The method of converting over-life public transport vehicles into electric vehicles Download PDF

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Publication number
WO2022146239A1
WO2022146239A1 PCT/TR2020/051413 TR2020051413W WO2022146239A1 WO 2022146239 A1 WO2022146239 A1 WO 2022146239A1 TR 2020051413 W TR2020051413 W TR 2020051413W WO 2022146239 A1 WO2022146239 A1 WO 2022146239A1
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WO
WIPO (PCT)
Prior art keywords
vehicle
electric
vehicles
electric motor
conversion method
Prior art date
Application number
PCT/TR2020/051413
Other languages
French (fr)
Inventor
Dursun ÇİÇEK
Original Assignee
Cicek Dursun
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 Cicek Dursun filed Critical Cicek Dursun
Priority to PCT/TR2020/051413 priority Critical patent/WO2022146239A1/en
Priority to EP21904635.6A priority patent/EP4061658A4/en
Priority to PCT/TR2021/051523 priority patent/WO2022146372A1/en
Publication of WO2022146239A1 publication Critical patent/WO2022146239A1/en

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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
    • 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
    • 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
    • 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
    • B60K2001/003—Arrangement or mounting of electrical propulsion units with means for cooling the electrical propulsion units
    • B60K2001/005—Arrangement or mounting of electrical propulsion units with means for cooling the electrical propulsion units the electric storage means
    • 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
    • B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
    • B60K2001/0411—Arrangement in the front part of the vehicle
    • 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
    • B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
    • B60K2001/0416—Arrangement in the rear part of the vehicle
    • 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
    • B60K2001/0455—Removal or replacement of the energy storages
    • 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
    • B60K2001/0455—Removal or replacement of the energy storages
    • B60K2001/0461—Removal or replacement of the energy storages from the side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2200/00—Type of vehicle
    • B60Y2200/10—Road Vehicles
    • B60Y2200/14—Trucks; Load vehicles, Busses
    • B60Y2200/143—Busses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2304/00—Optimising design; Manufacturing; Testing
    • B60Y2304/07—Facilitating assembling or mounting
    • B60Y2304/076—Facilitating assembling or mounting by add-on parts, e.g. retrofit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2304/00—Optimising design; Manufacturing; Testing
    • B60Y2304/07—Facilitating assembling or mounting
    • B60Y2304/078—Facilitating assembling or mounting by interchangeable parts, e.g. new part adapting to old design

Definitions

  • the invention is a state-of-the-art technology by converting the public transport vehicles which has reached service life, into 100% electric vehicles, by ensuring that these vehicles are renewed and at the same time, their service life is extended by repair and maintenance, that they are zero emission, environmentally friendly, silent and much more economical in terms of fuel and maintenance.
  • the invention is related to the method of converting the vehicle from fossil fuel to the electric vehicle.
  • the invention especially; disassembling the existing engine and gearbox of the vehicle that has reached its service life, the electric motor (10), which is installed in a protected area inside the body, thus is not affected by external impacts and provides automatic transmission convenience by eliminating the manual gear system, and the power is transmitted from the engine to the rear axle with the help of a shaft, the electric motor (10), which makes it move and it relates to a method of converting the vehicle into an electric vehicle comprising at least one battery pack (20) that transmits energy to this engine on the vehicle and thus realizes the movement of the vehicle with zero carbon emission.
  • Electric vehicle is the name given to vehicles that are driven by the electric motor. It is thought that electric vehicles will have a significant impact on the automotive industry in the near future. In addition to saving fuel in these types of vehicles, the city will reduce air and noise pollution as well as reduce carbon emission. The degree of reduction of carbon dioxide emissions depends on electricity generation, and there will be a 100% reduction in vehicles induced air pollution.
  • the electric motor is powered by the use of electricity stored by batteries, using a charger. Electric vehicles are vehicles that are driven using one or more electric motors, using electricity stored in batteries and other energy storage devices. Electric motors give instant torque, provide strong and stable acceleration.
  • one type of electric vehicles is electric public transportation vehicles, which is an important factor in reducing air pollution in urban public transportation.
  • hub motor embedded in the rear axle is used instead of an independent electric motor.
  • this method which provides ease of installation, it is very likely that the motor will be damaged by impacts and there is a difficulty in repair and maintenance due to its compact structure, and it is necessary to be dependent on a few companies that produce axles with hub motors in the world. Since independent electric motor is used in this application, there will be no supplier limitation and maintenance and repair will be made easier.
  • the present invention is about the renewal of the end-of-life public transport vehicles developed to eliminate the above-mentioned disadvantages and to bring new advantages to the relevant technical area, and to convert the existing vehicle into an environmentally friendly, silent and economically advanced technology %100 electric vehicle by performing maintenance and repair.
  • the most important aim of the invention is to renew and repair vehicles that have reached the end of their useful life, to make them reusable as fully environmentally friendly, which is much more cost-effective than new electric buses. Therefore, especially Municipalities and Private Public Buses will be converted into %100 electric vehicles in a short time and at very low costs. During the conversion, the original static and dynamic characteristics of the vehicle will remain the same, and the life of the vehicle will be extended with additional modifications, repairs and maintenance.
  • the other important purpose of the invention is to provide the production of environmentally friendly vehicles that reduce carbon emissions to zero by using electricity. If a diesel bus is predicted to travel 100,000 km annually, the greenhouse gas emitted is equivalent to the benefit of 1,500 trees. With the electric bus, both the environment and human health will be saved from carbon emissions.
  • Another important purpose of the invention is to minimize the noise in the city. While there is a serious noise level created by diesel public transport vehicles in the city, the electric vehicle noise level is up to 15 dB lower than the diesel vehicle, so there is a sound level below human perception in the %100 electric bus.
  • Another important purpose of the invention is to observe advanced and continuously renewed technological applications in the fields of mechanical, electrical, electronic, materials and software in %100 electric bus application. In this way, we are involved in scientific and technological studies that are constantly renewed in these and similar technological fields.
  • Another important aim of the invention is to minimize the annual heavy maintenance and fuel costs of old diesel vehicles with the conversion process to be made.
  • the annual maintenance and fuel difference between diesel vehicle and electric vehicle is approximately up to 5 times.
  • the other important purpose of the invention is to give the battery weight to the engine room of the vehicle.
  • different applications are made than the known applications in new electric buses.
  • the battery weight (between 1.5-2.5 tons) is usually given to the roof of the vehicle, while the engine room of the vehicle is used in the converted vehicles. In this way, the center of gravity of the vehicle is closer to the ground compared to its original design and the risk of overturning and collision is further reduced compared to the original vehicle.
  • Another important purpose of the invention is that an independent/external electric motor is used and the possibility of being affected by external impacts is very low since the motor is mounted in a protected area inside the body.
  • the number of suppliers for the electric motor is quite high, its cost is low and there will be no supply problem, and it will not need a special design according to the vehicle model and segment. It will be a very advantageous application in terms of supplying and localizing the electric motor.
  • Another important aim of the invention is that it is 70-75% more economical/cheaper than the cost of new electric public transport vehicles.
  • Another important purpose of the invention is to make it easier for the vehicle to get running into the traffic and obtain a passenger transport license, since the body, original parts and chassis otherthan the vehicle's diesel engine and gearbox are used as original.
  • connection brackets of the engine to the vehicle, the special design connection and power transmission systems between the electric motor and the original rear axle joints are specially designed.
  • Another important aim of the invention is that conversion and production process competence of 100% electric buses from fossil fuels for each brand and segment bus with the conversion authorization to be obtained, as well as conversion technology and production process competence of smaller segment vehicles are registered.
  • Another important purpose of the invention is to extend the service life of the vehicle by at least 15 years by means of repair, modification and maintenance operations performed for the renewal of the vehicle, but not mandatory for conversion.
  • the worn and corroded base, chassis and systems are completely renewed and reinforced with new protectors, and the service life is extended.
  • Another important object of the invention is to ensure that the converted vehicle is lighter by more than about 1.000 kg compared to the original vehicle, while maintaining its originality.
  • it was designed and implemented in a way to provide homogeneous load distribution in the vehicle in additional loads.
  • the fuel tank which carries 1 ton of load in the full condition, carries a weight on one side, all battery packs are distributed evenly from the front of the vehicle to the rear, similarly, the same load balance is observed in the systems placed in place of the diesel engine and transmission.
  • Another important purpose of the invention is to create a production system for conversion and to standardize it. Thus, the production process with the same method can be applied in the conversion processes of any similar segment and model vehicle to be converted.
  • FIGURE 1 The subject of the invention is the drawing showing the conversion of public transportation vehicles that have completed their useful life into %100 electric vehicles.
  • FIGURE 2 The subject of the invention is the drawing showing the conversion of public transportation vehicles that have completed their useful life into %100 electric vehicles.
  • FIGURE 3 It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
  • FIGURE 4 It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
  • FIGURE 5 It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
  • FIGURE 6 It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
  • FIGURE 7 It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
  • FIG. 1-7 shows the conversion system and details of the public transportation vehicles, subject of the invention, which have reached their end of life, to %100 electric vehicles.
  • the existing engine and transmission of the old vehicle are dismantled.
  • the original parts, chassis, body and axles of the vehicle are used same as original.
  • Batteries (20) developed for public transportation vehicles replace diesel fuels and convert the energy obtained from renewable energy sources or the sun into electrical energy, filling the batteries (20). As a result of the storage of the batteries (20) with electrical energy, it transmits energy to the electric motor (10) on the vehicle and the electric motor (10) thus provides the movement of the vehicle.
  • These battery packs (20) are preferably connected in series with each other and the fourth battery pack (+) (20) end remains idle, preferably the other 4 batteries (10) are also connected in series with each other and here the last battery (-) ( 20) The tip remains idle.
  • These + and - ends are brought together in the system where the energies we call Power Distribution Box (60) are collected parallel to each other.
  • the high voltage energy collected here is transferred to the inverter 70.
  • the voltage in the inverter (70) is increased, passing through the motor control unit (80) and power flow is provided to the electric motor (10).
  • movement is transmitted to the rear axle of the vehicle and the vehicle moves.
  • the inverter (70) acts according to the data from the vehicle, according to the system requirement that converts the high energy coming from the batteries (20) to AC / AC, DC / DC, AC / DC, DC / AC or to low voltage according to the need. It plays an important role in transferring the energy coming from the motor control unit (80) through the batteries (20) to the electric motor (10) in a controlled manner. Since the system also gets very hot, a liquid-cooled system is used. In this way, a long life is ensured. In our invention, the energy taken from the batteries (20) is fed to the electric motor (10) by means of the converter systems, and power is transmitted to the original axle on the vehicle.
  • the vehicle is moved by transmitting power to the rear axle from the electric motor (10) with the help of a shaft.
  • an independent electric motor (10) is used, thus the possibility of being affected by external impacts is very low since the electric motor (10) is mounted in a protected area inside the body. It will also be a very advantageous application in terms of supply alternatives and localization of the electric motor (10).
  • the manual gearbox system is eliminated and the automatic gearbox integrated into the electric motor (10) provides ease.
  • the air compressor (30) enables vehicle wheels and doors to move rapidly. In addition, it supports the filling of air in the air tanks in the vehicle system and vehicle movement.
  • the air compressor (30) which is not on the electric motor (10) but is located externally, provides convenience in maintenance and replacement. In this way, the maintenance of the vehicle takes place in a short time and it can continue to work in a short time.
  • This external air compressor (30) ensures the movement of the vehicle in a short time by filling the air required for the vehicle in a shorter time. It provides the ease of turning of the steering wheel with the steering pump (40) in order to direct the wheels that control the vehicle movement. It is always an advantage if the steering pump is located in the lower part of the steering area. In addition, ease of maintenance will be provided. In our invention, passengers, mobile phones etc. devices can be charged quickly with the USB input drawn from the 24V system.
  • the heater With the heater integrated externally, the vehicle is heated more quickly.
  • the heater (frontbox) (50) we have added to the system will provide rapid heating of the vehicle due to its high voltage operation.
  • passenger comfort is provided by the rapid thawing of the vehicle windows, which are frozen especially in winter, and the rapid heating of the vehicle interior.
  • the battery packs (20) on the vehicle are also controlled through the system we call BMS (Battery Management System), and warns the vehicle user by notifying the control panel of the balanced charge of the batteries and any data loss that may occur. With this system, the batteries (20) are constantly under control.
  • the inverter (70), engine control unit (80) and electric motor (10) on the vehicle are cooled with water the existing cooling system.
  • this cooling system vehicle systems are constantly kept at the same temperature level. All the movements of the vehicle and the required data of the all system on it can be seen on the driver control panel instantly.
  • the 24V electricity and communication (CANDATA) on the vehicle is redesigned and edited specifically for the converted bus.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)

Abstract

The invention is about converting public transport vehicles that have reached the end of their useful lifetime into %100 electric vehicles, renewing these vehicles, at the same time making the necessary maintenance, and repair, making them environmentally friendly, silent and much more economical, and converting them into a vehicle containing advanced technology. By dismantling existing engine and gearbox of the old vehicle that has reached end of its service time life, it is installed in a protected area inside the body and is therefore not affected by external impacts, with the power received from an electric motor, which enables the vehicle to move by transmitting power to the rear axle with the help of the shaft, eliminating the manual gear system and providing automatic gear convenience, at least one electric motor (10) and at least one battery pack (20) that provides the movement of the vehicle with zero emission by transmitting energy to the electric motor (10) on the vehicle.

Description

THE METHOD OF CONVERTING OVER-LIFE PUBLIC TRANSPORT VEHICLES INTO ELECTRIC VEHICLES
TECHNICAL AREA
The invention is a state-of-the-art technology by converting the public transport vehicles which has reached service life, into 100% electric vehicles, by ensuring that these vehicles are renewed and at the same time, their service life is extended by repair and maintenance, that they are zero emission, environmentally friendly, silent and much more economical in terms of fuel and maintenance. The invention is related to the method of converting the vehicle from fossil fuel to the electric vehicle.
The invention especially; disassembling the existing engine and gearbox of the vehicle that has reached its service life, the electric motor (10), which is installed in a protected area inside the body, thus is not affected by external impacts and provides automatic transmission convenience by eliminating the manual gear system, and the power is transmitted from the engine to the rear axle with the help of a shaft, the electric motor (10), which makes it move and it relates to a method of converting the vehicle into an electric vehicle comprising at least one battery pack (20) that transmits energy to this engine on the vehicle and thus realizes the movement of the vehicle with zero carbon emission.
STATE OF ART
Electric vehicle is the name given to vehicles that are driven by the electric motor. It is thought that electric vehicles will have a significant impact on the automotive industry in the near future. In addition to saving fuel in these types of vehicles, the city will reduce air and noise pollution as well as reduce carbon emission. The degree of reduction of carbon dioxide emissions depends on electricity generation, and there will be a 100% reduction in vehicles induced air pollution. The electric motor is powered by the use of electricity stored by batteries, using a charger. Electric vehicles are vehicles that are driven using one or more electric motors, using electricity stored in batteries and other energy storage devices. Electric motors give instant torque, provide strong and stable acceleration. Nowadays, one type of electric vehicles is electric public transportation vehicles, which is an important factor in reducing air pollution in urban public transportation.
A work has not yet been carried out on converting the expired public transportation vehicles into 100% electric vehicles in accordance with the current conversion technique and bringing the fossil fuel vehicles to be pulled from the traffic back into the economy. In the green public rules agreement signed by the EU commission for the new urban public transportation; local authorities were asked to supply gas or electricity powered environmental vehicles between 2025 and 2030. This situation will cause the withdrawal of fossil fuel vehicles from traffic both in Turkey and in the world, and therefore will cause a great economic loss and cost. If new electric vehicles are purchased instead of fossil fuel vehicles as a result of withdrawing from traffic, the costs will be high, which will force investors in the sector.
Currently, the purchase cost of new electric public transport vehicles is quite high. In particular, it does not seem economically feasible for a long period of time that the public and private sector vehicles with fleets should be banned from traffic at the same time and replaced by environmentally friendly 100% electric vehicles.
In new electric public transport vehicles produced in the current technique and in conversion works, hub motor embedded in the rear axle is used instead of an independent electric motor. With this method, which provides ease of installation, it is very likely that the motor will be damaged by impacts and there is a difficulty in repair and maintenance due to its compact structure, and it is necessary to be dependent on a few companies that produce axles with hub motors in the world. Since independent electric motor is used in this application, there will be no supplier limitation and maintenance and repair will be made easier.
As a result, electric buses produced with the current production technique, for the solution of the above-mentioned problems and insufficiency of existing solutions; It was necessary to convert the expired public transport vehicles that has reached the end of its life into 100% electric vehicles, and for a new economic and useful cycle, technical development and improvement in the relevant technical area was required.
PURPOSE OF INVENTION
The present invention is about the renewal of the end-of-life public transport vehicles developed to eliminate the above-mentioned disadvantages and to bring new advantages to the relevant technical area, and to convert the existing vehicle into an environmentally friendly, silent and economically advanced technology %100 electric vehicle by performing maintenance and repair.
The most important aim of the invention is to renew and repair vehicles that have reached the end of their useful life, to make them reusable as fully environmentally friendly, which is much more cost-effective than new electric buses. Therefore, especially Municipalities and Private Public Buses will be converted into %100 electric vehicles in a short time and at very low costs. During the conversion, the original static and dynamic characteristics of the vehicle will remain the same, and the life of the vehicle will be extended with additional modifications, repairs and maintenance.
The other important purpose of the invention is to provide the production of environmentally friendly vehicles that reduce carbon emissions to zero by using electricity. If a diesel bus is predicted to travel 100,000 km annually, the greenhouse gas emitted is equivalent to the benefit of 1,500 trees. With the electric bus, both the environment and human health will be saved from carbon emissions.
Another important purpose of the invention is to minimize the noise in the city. While there is a serious noise level created by diesel public transport vehicles in the city, the electric vehicle noise level is up to 15 dB lower than the diesel vehicle, so there is a sound level below human perception in the %100 electric bus.
Another important purpose of the invention is to observe advanced and continuously renewed technological applications in the fields of mechanical, electrical, electronic, materials and software in %100 electric bus application. In this way, we are involved in scientific and technological studies that are constantly renewed in these and similar technological fields.
Another important aim of the invention is to minimize the annual heavy maintenance and fuel costs of old diesel vehicles with the conversion process to be made. The annual maintenance and fuel difference between diesel vehicle and electric vehicle is approximately up to 5 times.
The other important purpose of the invention is to give the battery weight to the engine room of the vehicle. In the electric bus conversion, different applications are made than the known applications in new electric buses. In new electric buses, the battery weight (between 1.5-2.5 tons) is usually given to the roof of the vehicle, while the engine room of the vehicle is used in the converted vehicles. In this way, the center of gravity of the vehicle is closer to the ground compared to its original design and the risk of overturning and collision is further reduced compared to the original vehicle.
Another important purpose of the invention is that an independent/external electric motor is used and the possibility of being affected by external impacts is very low since the motor is mounted in a protected area inside the body. The number of suppliers for the electric motor is quite high, its cost is low and there will be no supply problem, and it will not need a special design according to the vehicle model and segment. It will be a very advantageous application in terms of supplying and localizing the electric motor.
Another important aim of the invention is that it is 70-75% more economical/cheaper than the cost of new electric public transport vehicles.
Another important purpose of the invention is to make it easier for the vehicle to get running into the traffic and obtain a passenger transport license, since the body, original parts and chassis otherthan the vehicle's diesel engine and gearbox are used as original.
Another important purpose of the invention is due to the use of the new external electric motor; The connection brackets of the engine to the vehicle, the special design connection and power transmission systems between the electric motor and the original rear axle joints are specially designed.
Another important aim of the invention is that conversion and production process competence of 100% electric buses from fossil fuels for each brand and segment bus with the conversion authorization to be obtained, as well as conversion technology and production process competence of smaller segment vehicles are registered.
Another important purpose of the invention is to extend the service life of the vehicle by at least 15 years by means of repair, modification and maintenance operations performed for the renewal of the vehicle, but not mandatory for conversion. Here, the worn and corroded base, chassis and systems are completely renewed and reinforced with new protectors, and the service life is extended.
Another important object of the invention is to ensure that the converted vehicle is lighter by more than about 1.000 kg compared to the original vehicle, while maintaining its originality. In addition, it was designed and implemented in a way to provide homogeneous load distribution in the vehicle in additional loads. For example, while the fuel tank, which carries 1 ton of load in the full condition, carries a weight on one side, all battery packs are distributed evenly from the front of the vehicle to the rear, similarly, the same load balance is observed in the systems placed in place of the diesel engine and transmission. Another important purpose of the invention is to create a production system for conversion and to standardize it. Thus, the production process with the same method can be applied in the conversion processes of any similar segment and model vehicle to be converted.
The structural and characteristic properties and all advantages of the invention will be understood more clearly supported to the figures given below and the detailed explanation written by referring to these figures, and therefore the evaluation should be made by taking these figures and detailed explanations into consideration.
FIGURES TO HELP UNDERSTAND THE INVENTION
FIGURE 1; The subject of the invention is the drawing showing the conversion of public transportation vehicles that have completed their useful life into %100 electric vehicles.
FIGURE 2; The subject of the invention is the drawing showing the conversion of public transportation vehicles that have completed their useful life into %100 electric vehicles.
FIGURE 3; It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
FIGURE 4; It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
FIGURE 5; It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
FIGURE 6; It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention.
FIGURE 7; It is the drawing showing the systems of the public transportation vehicle that has converted into an %100 electric bus subject of the invention. REFERANS NUMARALARI
10. Electric Motor
20. Battery Pack
30. Air Compressor
40. Steering Pump
50. Heater
60. Power Distribution Box
70. Inverter
80. Engine Control Unit
BULUJUN DETAYLI AQIKLAMASI
In this detailed explanation, the preferred changes of public transport that have reached the end of their life-time in the cycle system to %100 electric vehicles are explained only for a better understanding of the subject and in such a way that they have no limiting effect.
Figure 1-7 shows the conversion system and details of the public transportation vehicles, subject of the invention, which have reached their end of life, to %100 electric vehicles. In our invention, the existing engine and transmission of the old vehicle are dismantled. Other than these, the original parts, chassis, body and axles of the vehicle are used same as original. There are preferably 8 batteries (20) integrated on the vehicle, depending on the required power. Batteries (20) developed for public transportation vehicles replace diesel fuels and convert the energy obtained from renewable energy sources or the sun into electrical energy, filling the batteries (20). As a result of the storage of the batteries (20) with electrical energy, it transmits energy to the electric motor (10) on the vehicle and the electric motor (10) thus provides the movement of the vehicle. These battery packs (20) are preferably connected in series with each other and the fourth battery pack (+) (20) end remains idle, preferably the other 4 batteries (10) are also connected in series with each other and here the last battery (-) ( 20) The tip remains idle. These + and - ends are brought together in the system where the energies we call Power Distribution Box (60) are collected parallel to each other. The high voltage energy collected here is transferred to the inverter 70. The voltage in the inverter (70) is increased, passing through the motor control unit (80) and power flow is provided to the electric motor (10). Thus, movement is transmitted to the rear axle of the vehicle and the vehicle moves. Here, the inverter (70) acts according to the data from the vehicle, according to the system requirement that converts the high energy coming from the batteries (20) to AC / AC, DC / DC, AC / DC, DC / AC or to low voltage according to the need. It plays an important role in transferring the energy coming from the motor control unit (80) through the batteries (20) to the electric motor (10) in a controlled manner. Since the system also gets very hot, a liquid-cooled system is used. In this way, a long life is ensured. In our invention, the energy taken from the batteries (20) is fed to the electric motor (10) by means of the converter systems, and power is transmitted to the original axle on the vehicle. The vehicle is moved by transmitting power to the rear axle from the electric motor (10) with the help of a shaft. In our invention, an independent electric motor (10) is used, thus the possibility of being affected by external impacts is very low since the electric motor (10) is mounted in a protected area inside the body. It will also be a very advantageous application in terms of supply alternatives and localization of the electric motor (10). In addition, with our invention, the manual gearbox system is eliminated and the automatic gearbox integrated into the electric motor (10) provides ease. With our invention, a vehicle that is environmentally friendly, reduces carbon emissions to zero by using electricity and is silent vehicle is produced. In our invention, the air compressor (30) enables vehicle wheels and doors to move rapidly. In addition, it supports the filling of air in the air tanks in the vehicle system and vehicle movement. In the converted vehicle, the air compressor (30), which is not on the electric motor (10) but is located externally, provides convenience in maintenance and replacement. In this way, the maintenance of the vehicle takes place in a short time and it can continue to work in a short time. This external air compressor (30) ensures the movement of the vehicle in a short time by filling the air required for the vehicle in a shorter time. It provides the ease of turning of the steering wheel with the steering pump (40) in order to direct the wheels that control the vehicle movement. It is always an advantage if the steering pump is located in the lower part of the steering area. In addition, ease of maintenance will be provided. In our invention, passengers, mobile phones etc. devices can be charged quickly with the USB input drawn from the 24V system. With the heater integrated externally, the vehicle is heated more quickly. The heater (frontbox) (50) we have added to the system will provide rapid heating of the vehicle due to its high voltage operation. In our invention, with the electric heater (50), passenger comfort is provided by the rapid thawing of the vehicle windows, which are frozen especially in winter, and the rapid heating of the vehicle interior. The battery packs (20) on the vehicle are also controlled through the system we call BMS (Battery Management System), and warns the vehicle user by notifying the control panel of the balanced charge of the batteries and any data loss that may occur. With this system, the batteries (20) are constantly under control. In addition, due to the high voltage electricity in the system, the inverter (70), engine control unit (80) and electric motor (10) on the vehicle are cooled with water the existing cooling system. With this cooling system, vehicle systems are constantly kept at the same temperature level. All the movements of the vehicle and the required data of the all system on it can be seen on the driver control panel instantly. In addition, the 24V electricity and communication (CANDATA) on the vehicle is redesigned and edited specifically for the converted bus.
This study can be applied to all public transportation vehicles in Turkey and in the world. Under protection; It covers the conversion of fossil-fueled public transportation vehicles in each model and segment into 100% electric vehicles, as well as the production processes and methods included in the conversion studies. The scope of protection of this application is determined in the claims, and it cannot be limited to what is explained above strictly for sampling purposes, it is obvious that a person skilled in the art can reveal the innovation presented in the invention by using similar configurations and / or apply this structure to other similar fields used in the relevant technique. Therefore, it is obvious that such structures will lack the criteria of innovation and especially exceeding the known state of the art or technique.

Claims

CLAIMS - The invention is about the conversion of public transportation vehicles that have reached the end of their useful life into an electric vehicle with advanced technology, and its feature;
By removing the existing engine and gearbox of the old vehicle that has reached end of its service life, it is installed in a protected area inside the body and is therefore not affected by external impacts, with the power received from an electric motor, which enables the vehicle to move by transmitting power to the rear axle with the help of the shaft, eliminating the manual gear system and providing automatic gear convenience, at least one electric motor (10) and at least one battery pack (20) that provides the movement of the vehicle with zero emission by transmitting energy to the electric motor (10) on the vehicle. characterized by containing. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized in that it comprises a power distribution box (60) that allows the energy coming from the batteries to be collected together. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; It is characterized by the fact that it contains an inverter (70) that converts the high energy coming from the power distribution box (60) to AC / AC, DC / DC, AC / DC, DC / AC and low voltage according to the system requirement and the data from the vehicle. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized by the fact that it contains an air compressor (30) that allows the air to be filled in the air tanks in the vehicle system and the rapid movement of the doors. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized in that it comprises a steering pump (40) that provides ease of rotation of the steering wheel for steering the wheels in vehicle control. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized by the rapid dissolution of vehicle windows, which are frozen especially in winter, and the heater (50) that provides passenger comfort by heating the vehicle interior quickly. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized by controlling the batteries (20), the balanced charging of the batteries, any malfunction or data loss that may occur in the batteries (20), and the battery management system that warns the vehicle user by notifying the control panel. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; it is characterized in that it comprises a cooling system that cools the inverter (70), motor control unit (80) and electric motor (10) with water. - The conversion method to electric vehicle according to Claim 1, and it is characterized in that; It is characterized by the fact that it contains a driver control panel that allows all movements of the vehicle and the data of the entire system on it to be seen instantly.
PCT/TR2020/051413 2020-12-28 2020-12-28 The method of converting over-life public transport vehicles into electric vehicles WO2022146239A1 (en)

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PCT/TR2020/051413 WO2022146239A1 (en) 2020-12-28 2020-12-28 The method of converting over-life public transport vehicles into electric vehicles
EP21904635.6A EP4061658A4 (en) 2020-12-28 2021-12-27 The system and method of converting over-life public transport vehicles into 100% electric vehicles
PCT/TR2021/051523 WO2022146372A1 (en) 2020-12-28 2021-12-27 The system and method of converting over-life public transport vehicles into 100% electric vehicles

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