Land vehicles incorporating removable powertrain units, powertrain units, and methods therefor

Patent metadata

Field	Value
Publication number	US-11654971-B2
Application number	US-202217961554-A
Country	US
Kind code	B2
Filing date	Oct 6, 2022
Priority date	Jan 6, 2020
Publication date	May 23, 2023
Grant date	May 23, 2023

Abstract

In certain embodiments, land vehicles are provided as delivery vehicles and/or utility vehicles. A land vehicle includes a frame structure having a front cage that defines an operator cabin and a rear floor positioned rearward of the front cage. The frame structure supports a plurality of wheels to permit movement of the vehicle relative to an underlying surface in use of the land vehicle. An underside of the frame structure is disposed in confronting relation with the underlying surface.

First claim

What is claimed is:

1. A method of assembling an electric vehicle including a frame structure to support a plurality of wheels and a powertrain unit attachable to the frame structure, the method comprising:
affixing a first electric motor of the powertrain unit directly to a cradle of the powertrain unit that has an open tray, wherein affixing the first electric motor directly to the cradle comprises directly affixing the first electric motor to the cradle such that the first electric motor extends outwardly beneath the open tray and is not completely enclosed by the open tray;
affixing a second electric motor of the powertrain unit directly to the cradle, wherein affixing the second electric motor directly to the cradle comprises directly affixing the second electric motor to the cradle such that the second electric motor extends outwardly beneath the open tray and is not completely enclosed by the open tray;
aligning the first electric motor and the second electric motor along a lateral axis; and
attaching the cradle with the first and second electric motors directly affixed thereto and aligned along the lateral axis to an underside of the frame structure,
wherein attaching the cradle to the underside of the frame structure includes (i) aligning the cradle with a longitudinal centerline of the frame structure such that each of the first and second electric motors is at least partially aligned with the longitudinal centerline and (ii) securing the cradle to the frame structure such that the underside of the frame structure is in flush contact with the open tray in a lateral direction parallel to the lateral axis from a first end of the open tray to a second end of the open tray opposite the first end.

2. The method of claim 1 , further comprising coupling a first axle of the powertrain unit to the first electric motor such that the first axle extends along the lateral axis and is arranged entirely outside the open tray.

3. The method of claim 2 , further comprising coupling a second axle of the powertrain unit to the second electric motor such that the second axle extends along the lateral axis and is arranged entirely outside the open tray.

4. The method of claim 3 , further comprising aligning the first electric motor, the second electric motor, the first axle, and the second axle along the lateral axis.

5. The method of claim 3 , further comprising:
coupling the first axle to a first wheel hub to which a first one of the plurality of wheels is mounted for rotation about the lateral axis; and
coupling the second axle to a second wheel hub to which a second one of the plurality of wheels is mounted for rotation about the lateral axis.

6. The method of claim 1 , wherein attaching the cradle with the first and second electric motors directly affixed thereto to the underside of the frame structure comprises:
arranging the first electric motor on a first side of the frame structure to provide rotational power to a first one of the plurality of wheels arranged on the first side of the frame structure; and
arranging the second electric motor on a second side of the frame structure to provide rotational power to a second one of the plurality of wheels arranged on the second side of the frame structure.

7. The method of claim 6 , wherein arranging the first electric motor on the first side of the frame structure comprises positioning the first electric motor closer to the first one of the plurality of wheels than the second one of the plurality of wheels.

8. The method of claim 7 , wherein arranging the second electric motor on the second side of the frame structure comprises positioning the second electric motor closer to the second one of the plurality of wheels than the first one of the plurality of wheels.

9. The method of claim 6 , further comprising coupling the first electric motor to the first one of the plurality of wheels without any transmission gearing interposed therebetween.

10. The method of claim 9 , further comprising coupling the second electric motor to the second one of the plurality of wheels without any transmission gearing interposed therebetween.

11. The method of claim 1 , wherein attaching the cradle with the first and second electric motors directly affixed thereto to the underside of the frame structure comprises removably mounting the first and second electric motors to the underside of the frame structure to permit detachment therefrom upon removal of the cradle from the underside of the frame structure.

12. The method of claim 1 , further comprising forming the frame structure, wherein forming the frame structure comprises forming a monocoque having a single-piece, monolithic structure that does not include an internal chassis.

13. A method of assembling an electric vehicle, the method comprising:
affixing a first electric motor of a powertrain unit of the vehicle directly to a cradle of the powertrain unit that has an open tray, wherein affixing the first electric motor directly to the cradle comprises directly affixing the first electric motor to the cradle such that the first electric motor extends outwardly beneath the open tray and is not completely enclosed by the open tray;
affixing a second electric motor of the powertrain unit directly to the cradle, wherein affixing the second electric motor directly to the cradle comprises directly affixing the second electric motor to the cradle such that the second electric motor extends outwardly beneath the open tray and is not completely enclosed by the open tray;
aligning the first electric motor and the second electric motor along a lateral axis; and
attaching the cradle with the first and second electric motors directly affixed thereto and aligned along the lateral axis to an underside of a frame structure of the vehicle,
wherein attaching the cradle to the underside of the frame structure includes (i) aligning the cradle with a longitudinal centerline of the frame structure such that each of the first and second electric motors is at least partially aligned with the longitudinal centerline and (ii) securing the cradle to the frame structure such that the underside of the frame structure, which extends continuously across the open tray and beyond opposite ends of the open tray in a lateral direction parallel to the lateral axis, is in flush contact with the open tray.

14. The method of claim 13 , further comprising coupling a first axle of the powertrain unit to the first electric motor such that the first axle extends along the lateral axis and is arranged entirely outside the open tray.

15. The method of claim 14 , further comprising coupling a second axle of the powertrain unit to the second electric motor such that the second axle extends along the lateral axis and is arranged entirely outside the open tray.

16. The method of claim 15 , further comprising aligning the first electric motor, the second electric motor, the first axle, and the second axle along the lateral axis.

17. The method of claim 15 , further comprising:
coupling the first axle to a first wheel hub to which a first one of the plurality of wheels is mounted for rotation about the lateral axis; and
coupling the second axle to a second wheel hub to which a second one of the plurality of wheels is mounted for rotation about the lateral axis.

18. The method of claim 13 , wherein attaching the cradle to the underside of the frame structure comprises:
arranging the first electric motor on a first side of the frame structure to provide rotational power to a first one of the plurality of wheels arranged on t

Assignees

• Workhorse Group Inc

Inventors

• Wires Donald L

Classifications

• B29L2031/3055

  Cars · CPC title

• B62D29/046

  Combined superstructure and frame, i.e. monocoque constructions · CPC title

• B62D29/043

  Superstructures (B62D25/161 takes precedence) · CPC title

• B62D29/02

  predominantly of wood · CPC title

• B62D25/20

  Floors or bottom sub-units {(sub-frames for mounting engine or suspensions B62D21/11; drip trays F16N31/006)} · CPC title