Modular vehicle architecture enabling range on demand

Patent metadata

Field	Value
Publication number	US-11987306-B2
Application number	US-201917293935-A
Country	US
Kind code	B2
Filing date	Nov 14, 2019
Priority date	Nov 14, 2018
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

A system for modifying the range capability of an electric vehicle includes a vehicle body having a front axle and a rear module secured to the vehicle body. The rear module includes a rear axle and the rear module is detachable from the vehicle body and replaceable with another rear module. The rear modules may include different range extension capabilities. The rear modules may include a battery or a combustion engine that may supplement the standard battery and electric motor of the vehicle. A pair of laterally translatable pins of the rear module may be moveable into and out of engagement with the vehicle body. The rear module may also include vertically extending posts that engage with the vehicle body. The vehicle body may be raised to disengage the posts from the vehicle body.

First claim

What is claimed is:

1. A system for modifying the range capabilities of an electric vehicle, the system comprising:
a vehicle body having a vehicle structure and a first axle, wherein the first axle is one of a front axle or a rear axle, the vehicle body defining a fore-and-aft direction, and a lateral direction, wherein the front and rear axle each extend in the lateral direction;
a first removable module having a second axle, wherein the second axle is the other of the front axle or the rear axle, the first removable module detachably coupled to the vehicle structure, wherein the first removable module and the vehicle structure are attached at a plurality of attachment points;
an electrical connector disposed at an interface between the vehicle body and the first removable module for electrically connecting the vehicle body to the first removable module;
wherein the first removable module is removable from the vehicle structure when the first removable module is disengaged from the vehicle structure at the attachment points and the electrical connector is disengaged; and
wherein the first removable module is replaceable with a second removable module having range extending systems that differ from the first removable module;
wherein the plurality of attachment points include:
at least one vertically aligned post received within a vertically aligned bore, and
at least one laterally aligned pin received within a laterally aligned bore, wherein the laterally aligned pin and laterally aligned bore each extend axially in the lateral direction;

wherein, with the removable module in a stationary fore-and-aft position, the vehicle body is moveable vertically upward relative to the first removable module and disengages the vertically aligned post from the vertically aligned bore when the laterally aligned pin is moved in the lateral direction out of the laterally aligned bore and disengaged from the laterally aligned bore.

2. The system of claim 1 , wherein there are no hydraulic or other fluid connections between the vehicle body and the first removable module, and there are no cable connections between the vehicle body and the first removable module other than the electrical connector.

3. The system of claim 1 , wherein the plurality of attachment points includes a pair of upper attachment points and a pair of lower attachment points configured to enable connection of second rear modules having a wide dimensional tolerance at the attachment points.

4. A system for modifying the range capabilities of an electric vehicle, the system comprising:
a vehicle body having a vehicle structure and a first axle, wherein the first axle is one of a front axle or a rear axle;
a first removable module having a second axle, wherein the second axle is the other of the front axle or the rear axle, the first removable module detachably coupled to the vehicle structure, wherein the first removable module and the vehicle structure are attached at a plurality of attachment points;
an electrical connector disposed at an interface between the vehicle body and the first removable module for electrically connecting the vehicle body to the first removable module;
wherein the first removable module is removable from the vehicle structure when the first removable module is disengaged from the vehicle structure at the attachment points and the electrical connector is disengaged; and
wherein the first removable module is replaceable with a second removable module having range extending systems that differ from the first removable module;
wherein the plurality of attachment points includes a pair of upper attachment points and a pair of lower attachment points configured to enable connection of second rear modules having a wide dimensional tolerance at the attachment points;
wherein each of the lower attachment points is defined by a ball joint linkage with a vertical post of the first removable module received in a bore of a block member of the vehicle body.

5. The system of claim 4 , wherein each of the upper attachment points is defined by a retractable pin of the first removable module received in a bore of a bracket of the vehicle body.

6. The system of claim 5 , wherein the pin is moveable laterally inward and outward relative to a support frame of the first removable module between an engaged position in which the pin is received within the bracket and a disengaged position in which the pin is not received within the bracket.

7. The system of claim 6 , wherein the pin is moveable via an actuation mechanism having a brain plate mechanism coupled to the pins, wherein rotation of the brain plate mechanism in a first direction moves the pins toward the disengaged position, and rotation of the brain plate mechanism in a second direction moves the pins toward the engaged position, wherein the pins are biased toward the engaged position, wherein movement of the pins toward the disengaged position includes compressing and loading a spring member and moving the pin upon de-compression of the spring when the brain plate is rotated.

8. The system of claim 6 , wherein the pins retain the first removable module relative to the vehicle body at least in a fore-and-aft direction and a vertical direction, and the posts retain the first removable module relative to the vehicle body at least in a lateral direction and fore-and-aft direction.

9. The system of claim 8 , wherein, when the pins are in the disengaged position, the vehicle body is moveable vertically relative to the first removable module to a disengaged state at each of the plurality of attachment points and the first removable module is moveable in the fore-and-aft direction away from the vehicle body.

10. The system of claim 9 , wherein the vehicle body includes a jack mechanism configured to extend downward into engagement with a physical surface disposed below the vehicle body, wherein extension of the jack mechanism moves the vehicle body upward to disengage the vehicle body from the posts of the first removable module when the pins of the first removable module are disengaged.

11. The system of claim 1 , wherein the second removable module includes a combustion engine configured to provide range extension capabilities relative to the first removable module.

12. The system of claim 1 , wherein the second removable module includes a battery having a greater range capability than the first removable module.

13. A method for modifying a range capability of an electric vehicle, the method comprising the steps of:
providing a vehicle body having a vehicle structure and a first axle extending in a lateral direction of the vehicle;
providing a first removable module having a second axle extending in the lateral direction, wherein the first removable module is secured to the vehicle structure at a plurality of attachment points and detachable from the vehicle structure, wherein the plurality of attachment points includes laterally extending pins received in laterally extending bores and that are moveable in the lateral direction;
providing an electrical connection between the vehicle structure and the removable module via an electrical connector;
raising and detaching the first removable module from the vehicle structure at each of the attachment points while the first removable module remains in a stationary fore and aft position;
disengaging the electrical connection between the vehicle structure and the first removable module;
removing the first removable module from the vehicle structure; and
replacing the first removable module with a second removable module, wherein the second removable module includes range extending compone

Assignees

• Magna Int Inc
• Subramanian Azhagu
• Meka Rahul
• Stiverson Joel
• Gabbianelli Gianfranco

Inventors

• Subramanian Azhagu
• Meka Rahul
• Stiverson Joel
• Gabbianelli Gianfranco

Classifications

• B62D63/025 Primary

  Modular vehicles (superstructures for busses having modular sections B62D31/025) · CPC title

• B60K5/00

  Arrangement or mounting of internal-combustion or jet-propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) · CPC title

• B60L50/64

  Constructional details of batteries specially adapted for electric vehicles · CPC title

• B60S9/02

  for only lifting or supporting · CPC title

• B60L50/66 Primary

  Arrangements of batteries · CPC title