Patent Application
20090166108
The present invention relates to the design and construction of an all terrain vehicle (“ATV”). More specifically, the present invention relates to inverter generators on ATVs.
Presently, if an ATV operator desires to operate electrical appliances or devices they must carry a portable generator with them, especially in remote locations. Further, the operator will have to carry other accessories for the generator, such as gas and repair parts. This can be a burden for the ATV operator as it entails lifting a generator, some of which can be very heavy, onto the ATV, strapping the generator down, and strapping all the accessories down. This is a manually intensive process and a time consuming process as well. Further, the generator takes up a lot of space on the ATV. This is space that could be used for other things, such as camping gear, tools, or other desired items. By strapping a heavy generator to the top of the vehicle, the ride and handling characteristics of the vehicle may also be reduced due to altering the center of gravity of the vehicle. Therefore, it is desirable to eliminate the need to carry a portable generator on an ATV to power electrical accessories.
Smaller generators have been implemented into vehicles such as that shown in U.S. Patent Publication 2005/0103553A1 titled, “Component Arrangement for an All Terrain Vehicle”. This publication discusses the issues associated with space constraints in small vehicles, such as ATV's, and discloses a power generation layout in an ATV that incorporates a small 400 Watt generator driven off of the engine crankshaft. This compact generator arrangement provides additional vehicle benefits such as if battery fails; however, it still does not provide enough power generation to operate additional electrical devices similar to those that may be utilized by separate portable generators. Others have also tried to retrofit vehicles by affixing portable generators into portions of the chassis (e.g., front, rear) such that they may be connected directly to the vehicle fuel supply. Although these systems resolve the issues of constantly loading the generators and having to carry additional fuel to operate the generator, they still have a large impact on the vehicle's dynamics and often reduce the amount of vehicle cargo space. Therefore, the need exists for an improved small vehicle engine and generator packaging arrangement that overcomes the problems others have not been able to address.
A vehicle in certain embodiments of the present teachings may include one or more of the following features: (a) a chassis, (b) at least one front ground engaging member and at least one rear ground engaging member coupled to the chassis, (c) a steering member for steering at least one of the ground engaging members, (d) an engine carried by the chassis for powering the vehicle, the engine including a cylinder disposed adjacent a crankshaft and an inverter generator operatively connected to the crankshaft, (e) an output shaft operatively coupled to the crankshaft to transmit power from the engine to at least one of the ground engaging members, and (f) a cover attached to the engine adjacent to the inverter generator, a cooling line disposed within the cover, and a fluid within the cooling line such that heat is transferred from the inverter generator to the fluid.
A vehicle in certain embodiments of the present teachings may include one or more of the following features: (a) an engine, (b) a transmission coupled to the engine, (c) at least one ground engaging member, (d) an output shaft selectively coupled to the transmission to transmit power from the engine to the at least one ground engaging member, (e) an inverter generator operatively coupled to the engine to transmit power to an electrical accessory, (f) a control system that selectively controls the speed of the engine in response to the electrical accessory, (g) a control panel including a switch that has a first position and a second position, wherein the control system does not control the speed of the engine when the switch is in the first position, (h) a control panel lid that can be moved between an open and closed position, wherein the switch is automatically moved to the first position when the control panel lid is closed, and (i) a vehicle brake selectively engaged to keep the vehicle in a stationary position, wherein the control system does not control the speed of the engine when the vehicle brake is not engaged.
A method of providing power to electrical accessories from a vehicle in certain embodiments of the present teachings may include one or more of the following steps: (a) placing the vehicle in an inverter generator mode, (b) determining if at least one electrical accessory has been plugged into the vehicle, (c) determining if the load of the at least one electrical accessory has increased, (d) increasing an engine RPM if the load of the electrical accessory has increased, (e) determining if the load of the at least one electrical accessory has decreased, (f) decreasing the engine RPM if the load of the electrical accessory decreased, (g) generating approximately 2,500 watts through an inverter generator to power the electrical accessories.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention. The following introductory material is intended to familiarize the reader with the general nature and some of the features of embodiments of the invention.
Although the description that follows is directed to an inline two cylinder, internal combustion engine, it should be noted that the invention is not limited to such. Instead, the features of the present invention may be applied to any type of internal combustion engine, as would be appreciated by those skilled in the art. For example, the features of the present invention may be applied to a single cylinder, v-type, opposed cylinder, multiple cylinder engine with more than two cylinders, or a rotary engine without deviating from the scope of the present invention.
In addition, while the engine of the present invention is specifically designed for use in an ATV, the present invention is not limited just to use on ATV's. To the contrary, the present invention may be used in any vehicle type, including cars, scooters, motorcycles, snowmobiles and other suitable vehicles.
Vehicle 100 can also include a first footrest 138 that can be seen extending from one side of the chassis 102 in
Vehicle 200 can also include a footrest 238 that can be seen extending from one side of the chassis 202 to the other side. Vehicle 200 can also include at least one mounting aperture 226. For example, mounting aperture 226 can be located on accessory platform 222 often referred to as a box. Box 222 can extend from the rear of the chassis for carrying various items. Box 222 can have mounting apertures 226 similar to accessory platforms 142 and 144 located on the top of bed rail. It is further contemplated; box 222 could have mounting apertures located within box 222, without departing from the spirit of the present teachings. Vehicle 200 can also include member 240 that may be used for steering vehicle 200. In the embodiment of
Other ground engaging members, left and right steerable skis 750 are carried by a front suspension system 740, which in turn is mounted to the chassis 731. The suspension system may be of any suitable type. In the drawings, a trailing arm suspension system is depicted, such a system utilizing, for each ski, a trailing arm 742 connected at its rear end to the chassis, a pair of generally transversely mounted radius rods 743 connected at their inner ends to the chassis and at their outer ends to the front end of the trailing arm, and a shock/spring combination 744 connected at one end to the chassis 731 and at the other end to the front end of the trailing arm 742. Other suitable suspensions could also be utilized, however, including, e.g., a double A-arm (sometimes called “double wishbone”) suspension or a telescopic strut suspension. With reference to
In the embodiments discussed below, an engine integrated portable supply feature is disclosed which will give the operator electrical power wherever they may travel to power most electrical tools, lights, and most other electrical equipment without the need to bring along a generator. The present invention discloses a generator having a flywheel and stator allowing the generator to produce roughly 2.5 KW (kilo-watts) of electrical power output.
The present invention discloses an integrated electrical power supply capable of supplying 120 V (volts) of AC (Alternating Current) external power to operate lights, small hand tools, appliances, and many other electrical accessories. Further, the generator is robust enough to continue maintaining vehicle electrical charging and operating power. The system, discussed in more detail below, is made up of a large magnetic flywheel and a large wound stator for generating approximately 2.5 KW of electrical power output. Also disclosed is an ICU (Inverter Control Unit) which communicates a signal to the ECU (Engine Control Unit), which in turn will tell the engine to accelerate up or down in engine rpm depending on the required output load to operate the electrical device that is plugged into the control panel. This system provides inexpensive mobile electrical power useful for, but not limited to remote applications. The integrated inverter system frees up storage and carrying capacity by eliminating the need to strap on a portable generator system and the needed fuel to run it.
With reference to
Magnet wheel 42 is constructed as a forged part and is attached to the crankshaft 12 at hub 46. The hub 46 is mounted onto a tapered portion of the crankshaft 12 and secured there by a nut 48. While the magnet wheel 42 can be connected to the crankshaft 12 in this manner, it is contemplated that the magnet wheel 42 could be connected to the crankshaft in any number of alternate ways without deviating from the scope of the present invention.
As discussed above, crankshaft 12 being rotated by engine 10 and is operatively connected to gear 22. Gear 22 is the engine drive gear and may be utilized for driving any engine auxiliary component, such as an oil pump, coolant pump, cam shaft or balance shaft. It may also be used to operatively connect to the starter motor for providing starting operation of engine 10. Bearing 18 is located between gear 22 and seal 24 which prevents any oil from the engine side getting into the generator 40. Bearing 18 provides additional support to counterbalance the additional weight of the enlarged flywheel. Seal 24 is adjacent to the hub 46 of the flywheel 42. Flywheel 42 is much larger from the typical design to create additional power to run attached accessories. Flywheel 42 has an increased diameter from the common diameter of 125 mm to 200 mm. Flywheel 42 also has an increased width from the common width of 53 mm to 75 mm. This additional diameter and width adds additional weight to flywheel 42 increasing its weight from 6.25 lbs to 9.8 lbs. The increased weight and diameter create several adversities. First the additional weight creates a rotational balance issue, and thus the need for bearing 18 to counteract the balance problem. Second, the increased size of the flywheel creates a heat generation issue due to the amount of current generated by the generator.
Adjacent to flywheel 42 is stator 44. Stator 44 is enlarged as well from a common diameter of 108 mm to 160 mm. Stator 44 also has an increased width from the common width of 46 mm to 55 mm. Due to the increased power generation of the enlarged flywheel and stator, they also generate more heat thus requiring additional cooling. Stator 44 is encased in generator 40 with cover 14. Cover 14 has coolant lines 16 which encircle outer cover 14. Coolant from the engine's coolant system runs through lines 16 to remove heat generated by generator 40. Mounting the stator 44 directly to the stator cover 14 allows for better heat dissipation of the stator 44 due to increasing the amount conduction through the stator cover 14. Furthermore, cooling lines 16 are strategically positioned within the stator cover 14 to maximize the heat transfer by increasing the surface area of the common wall of stator cover 14 between the stator 44 and cooling line 16, as well as, minimizing the wall thickness of this common wall area. It is understood that cooling line 16 obtains it's coolant from the ATV's coolant system, which are well known in the art, and are typically comprised of a closed loop cooling circuit in which a coolant pump circulates fluid through passageways of the engine where the fluid is heated and is then routed to an external heat exchanger (e.g., radiator) where the heat is dissipated.
In prior generator systems, the stator has also been known to mount directly to the engine. The crankshaft would pass through the center of the stator and the flywheel would be mounted in a cupped fashion facing towards the center of the engine. This arrangement takes the mass of the flywheel and puts it out on the end of the crankshaft. However, this design is less than desirable for the large flywheel of the present invention. An increased flywheel size would add weight and create bending and torsional stresses to the crankshaft. Therefore, in the present embodiment, the flywheel is preferably rotated 180 degrees so that the bulk of the mass in the hub 46 is close to the bearing support 18 of the crankshaft 12 and the cup of the flywheel is faced outward. This design allows for having a heavier flywheel and/or a smaller bearing support as the rotating mass of the inverter generator is moved closer to a supporting member of the engine (i.e., the bearing) thus reducing the bending moment on the crankshaft. Additionally, by switching the positions of the stator and flywheel such that they are flip-flopped compared to prior-art engines, the manufacturability of the engine is improved as the rotating components of the engine are more centralized.
With reference to
In operation, the rotation of crankshaft 12 turns flywheel 42. As stated above, stator 44 remains immobile while magnets 52 located on flywheel 42 spins about coils 320 of stator 44, which creates electricity. It is noted that even though flywheel 42 and stator 44 are larger, the overall weight of the vehicle when weighted down with a portable generator is decreased by approximately 90 lbs. That is to say that the present invention not only eliminates the need to carry a portable generator while maintaining the ability to produce the electricity of a portable generator, but the overall weight of the vehicle is only minimally increased. Therefore, even though the weight of the vehicle has increased, it is now easier for the operator to traverse the terrain and carry more items. For example, the operator can carry more accessories because they don't have a generator on the vehicle.
As stated above, this generator is unique in that it has a much larger flywheel and stator than traditional ATV generators. Further, the generator has a water-cooled outer stator cover to maintain and cool the stator to keep it from over heating. The system also has a power control panel for power distribution and monitoring system performance. In operation, the operator will place the vehicle in a stationary gear (e.g., neutral or park), start the vehicle, plug an electrical accessory into the control panel, and turn an inverter generator switch to inverter mode. The unit can have a load sensing system incorporated into the inverter generator control unit which will control and vary the engine rpm (roughly between 2000 to 4300 rpm as the electrical load demand increases or decreases). Thus, ATV 100 now becomes a combined vehicle and portable generator system.
Typical ATV generators can generate roughly 500 watts of DC (Direct Current). While this is enough to provide for the vehicle, it is not enough to support other accessories. The present invention proposes a larger generator and inverter capable of providing 2,500 watts of AC (Alternating Current) with a surge of 3000 watts of AC. This increased power generation allows for the 500 watts of DC to run the vehicle and by use of an inverter control box converts 2,500 watts of AC for operation of additional accessories (e.g., work tools). While the enlarged size of generator 40 provides some packaging obstacles, the inventors have found that these obstacles are minimal. For example, the packaging adjustments are minimal to the vehicle packaging, for example, the brake lever on the right hand side might need to be moved out or bent a bit to route around the stator cover 14. Additionally, a switch assembly 600 (discussed in more detail below) has been added to the front of ATV 100.
1 In another embodiment, with reference to
With reference to
An additional change in traditional ATV structure is the need to increase the gauge size wiring to handle the additional current generated by inverter generator 322 of the present invention. However, during normal operation, ATV generator 322 will produce 500 watts which is plenty to power ATV 300 during operation. That is to say certain coils of the stator 44 are solely set aside for running the vehicle and certain coils are dedicated to supplying power to external accessories 306. Therefore, the power output from a predetermined number of the coils 320 is directly connected to the battery, while the output of the remaining coils are branched to the ICU to convert the DC power to AC such that it may be fed to the external accessories 306.
With reference to
With reference to
Thus, embodiments of the MOBILE INVERTER GENERATOR are disclosed. One skilled in the art will appreciate that the present invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow.
