Hyper-Compact Electric All-Terrain Vehicle Drivetrain and Conversion Kit

Patent metadata

Field	Value
Publication number	US-2019366829-A1
Application number	US-201916280843-A
Country	US
Kind code	A1
Filing date	Feb 20, 2019
Priority date	Feb 20, 2018
Publication date	Dec 5, 2019
Grant date	—

Abstract

The present invention relates to electric drivetrain kits for converting all-terrain vehicles into hybrid or electric vehicles. In exemplary embodiments, a conversion kit replaces an existing standard single motor and transmission drive system with a dual set-up including a motor for each rear wheel and a split transmission that houses two sets of gear reduction components in a single housing or an all-wheel configuration with two transmission sets (front and rear). Dual output shafts in each transmission set drive the wheels independently to provide the torque needed as required and demanded by each wheel.

First claim

1 . A transmission comprising:
a first and a second outboard cover; a common center housing; a first and a second input shaft, wherein the first input shaft is disposed between the first outboard cover and common center housing, wherein the second input shaft is disposed between the second outboard cover and common center housing; a first and a second pinion, wherein the first and the second pinion couple to first and second input shaft, respectively; a first and a second gear, wherein the first and the second gear engage with the first and the second pinion, respectively; a third and a fourth pinion, wherein the third and the fourth pinion are coupled to the first and the second gear, respectively; a third and a fourth gear, wherein the third and the fourth gear engage with the third and the fourth pinion, respectively; and a first and a second output shaft coupled to the third and the fourth gear, respectively, wherein the first output shaft is disposed between the first outboard cover and common center housing, wherein the second output shaft is disposed between the second outboard cover and common center housing; wherein when a first motor is coupled to the first input shaft, the first motor controls the rotation of the first output shaft; wherein when a second motor is coupled to the second input shaft, the second motor controls the rotation of the second output shaft.

2 . A vehicle drivetrain conversion kit comprising:
a first transmission comprising a first input shaft, a second input shaft, a first output shaft, and a second output shaft, wherein the second transmission is configured to replace an original transmission such that the first output shaft is connected to a first wheel assembly and the second output shaft is connected to a second wheel assembly; at least one power source; an electronic control unit (ECU); wherein the ECU is configured to control the rotation of the first wheel assembly and the second wheel assembly.

3 . The conversion kit of claim 2 , further comprising:
a second transmission comprising a third input shaft, a fourth input shaft, a third output shaft, and a fourth output shaft, wherein the second transmission is configured to replace a rear transaxle such that the third output shaft is connected to a third wheel assembly and the fourth output shaft is connected to a fourth wheel assembly; wherein the ECU is further configured to control the rotation of the third wheel assembly and the fourth wheel assembly.

4 . The conversion kit of claim 3 , further comprising:
a tablet comprising an ECU user interface configured to control the ECU.

5 . The conversion kit of claim 3 ,
the first transmission further comprising:
a first and a second outboard cover;
a first common center housing;
wherein the first input shaft is disposed between the first outboard cover and common center housing, wherein the second input shaft is disposed between the second outboard cover and the first common center housing;
a first and a second pinion, wherein the first and the second pinion couple to first and second input shaft, respectively;
a first and a second gear, wherein the first and the second gear engage with the first and the second pinion, respectively;
a third and a fourth pinion, wherein the third and the fourth pinion are coupled to the first and the second gear, respectively; and
a third and a fourth gear, wherein the third and the fourth gear engage with the third and the fourth pinion, respectively;
wherein the first and the second output shaft are coupled to the third and the fourth gear, respectively, wherein the first output shaft is disposed between the first outboard cover and the first common center housing, wherein the second output shaft is disposed between the second outboard cover and the first common center housing;
wherein when a first motor is coupled to the first input shaft, the first motor controls the rotation of the first output shaft;
wherein when a second motor is coupled to the second input shaft, the second motor controls the rotation of the second output shaft;
the second transmission further comprising:
a third and a fourth outboard cover;
a second common center housing;
wherein the third input shaft is disposed between the third outboard cover and the second common center housing, wherein the fourth input shaft is disposed between the fourth outboard cover and the second common center housing;
a fifth and a sixth pinion, wherein the fifth and the sixth pinion couple to third and fourth input shaft, respectively;
a fifth and a sixth gear, wherein the fifth and the sixth gear engage with the fifth and sixth pinion, respectively;
a seventh and an eighth pinion, wherein the seventh and the eighth pinion are coupled to the fifth and the sixth gear, respectively; and
a seventh and an eighth gear, wherein the seventh and the eighth gear engage with the seventh and the eighth pinion, respectively;
wherein the third and the fourth output shaft are coupled to the seventh and the eighth gear, respectively, wherein the third output shaft is disposed between the third outboard cover and second common center housing, wherein the fourth output shaft is disposed between the fourth outboard cover and second common center housing;
wherein when a third motor is coupled to the third input shaft, the third motor controls the rotation of the third output shaft;
wherein when a fourth motor is coupled to the fourth input shaft, the fourth motor controls the rotation of the fourth output shaft.

6 . An all-terrain vehicle comprising:
a first, a second, a third, and a fourth motor; a first, a second, a third, and a fourth wheel assembly; a first transmission comprising a first input shaft, a second input shaft, a first output shaft, and a second output shaft, wherein the first output shaft is connected to the first wheel assembly and the second output shaft is connected to the second wheel assembly, wherein the first input shaft is coupled to the first motor and the second input shaft is coupled to the second motor; a second transmission comprising a third input shaft, a fourth input shaft, a third output shaft, and a fourth output shaft, wherein the third output shaft is connected to the third wheel assembly and the fourth output shaft is connected to the fourth wheel assembly, wherein the third input shaft is coupled to the third motor and the fourth input shaft is coupled to the fourth motor; at least one power source; an electronic control unit (ECU); a tablet comprising an ECU user interface configured to control the ECU wherein the ECU is configured to control the rotation of the first wheel assembly and the second wheel assembly by increasing power to the first motor and the second motor, respectively; wherein the ECU is further configured to control the rotation of the third wheel assembly and the fourth wheel assembly by increasing power to the third motor and the fourth motor, respectively.

7 . A method of converting all-terrain vehicles (ATVs) comprising:
providing an ATV and an ATV conversion kit; replacing an original gear case with a first transmission and replacing transaxle with second transmission; coupling a first at least one motor to the first transmission and a second at least one motor to the second transmission; replacing an original fuel tank with at least one battery pack; replacing a stock instrument cluster with a control module.

8 . The method of claim 8 ,
wherein the ATV conversion kit comprises:
the first transmission comprising a first input shaft, a second input shaft, a first output shaft, and a second output shaft, wherein the first output shaft is connected to the first wheel assembly and the second output shaft is connected t

Assignees

• Us Navy

Inventors

• Avenatti Peter
• Mullis Tyler
• Yake Braden
• Miller Jason
• Wynne Ryan
• Allison Lucas
• Bailey Joseph
• Bodey Alywin

Classifications

• B60Y2200/20

  Off-Road Vehicles · CPC title

• B60L2220/42

  with use of more than one motor · CPC title

• B60L50/75 Primary

  using propulsion power supplied by both fuel cells and batteries · CPC title

• B60L50/66

  Arrangements of batteries · CPC title

• B60Y2400/202

  Fuel cells · CPC title