Patent Application
20120217080
The present invention relates to a powertrain assembly for a powered vehicle, and in particular to a powered vehicle having an independent and interchangeable powertrain assembly.
For many vehicle manufacturers, vehicle performance is one of the most important criteria for selling its products to consumers. Along with vehicle performance, the durability and overall life of a vehicle's components is very important. Consumers do not want to drive a vehicle that is constantly breaking down and/or being serviced. Of course, vehicle components naturally begin to wear and require attention through continued use. On many vehicles, tires must be replaced or rotated every several thousands of miles. Likewise, gaskets, shafts, sparkplugs, and other components can break and require replacement.
In a conventional front loader, for example, the vehicle can have a front frame assembly and a rear frame assembly. A front axle is connected to the front frame assembly and a rear axle is connected to the rear assembly. Torque is transferred to each wheel by a drive assembly. The drive assembly includes gears, shafts, bearings, and other components that have a finite life. A motor or engine can provide power to the drive assembly for driving the wheels. Therefore, after the drive assembly and motor, for example, have operated for a number of hours and miles, the internal components of each begin to wear and can potentially fail. Service plans and the like are established to replace or service a component before it negatively impacts vehicle performance.
The ability to perform service on the different components that are connected to an axle can be difficult. For example, it can be cumbersome to remove an entire axle from the vehicle. In most instances, the front axle is different from the rear axle. In addition, each axle can be packaged differently (e.g., with different components) and each axle can mount differently to its respective frame assembly. The front axle of a conventional front loader, for example, can be fixed to the front frame assembly, whereas the rear axle oscillates with respect to the rear axle. This difference can require different connections and steps for removing and servicing the front axle compared to the rear axle. Due to the differences in the front and rear axles, the motors, drive assemblies, gear sets, etc. that mount to the front axle can be substantially different from those that mount to the rear axle.
In addition, the components may wear differently depending on the vehicle application and where on the vehicle each component is located. For instance, if a vehicle makes left turns 75% of the time, those components on the leftside of the vehicle can wear more quickly and thus have less durability than those components on the rightside of the vehicle. In other instances, the components coupled to the front axle can wear more quickly than the components coupled to the rear axle. Thus, the vehicle service plan can require the front axle to be serviced after fewer miles or hours of operation than the rear axle. This can increase the amount of vehicle downtime and therefore reduce overall vehicle productivity.
Thus, a need exists for an improving the durability and overall life of a vehicle powertrain assembly. A further need is to simplify the manner in which the powertrain is serviced to improve vehicle productivity.
In one exemplary embodiment of the present disclosure, a powered vehicle includes a first frame assembly and a second frame assembly. A first axle is coupled to the first frame assembly and a second axle is coupled to the second frame assembly. The vehicle also includes a first powertrain assembly and a second powertrain assembly. The first powertrain assembly and second powertrain assembly are interchangeably coupled to the first axle and second axle.
In one aspect, the first powertrain assembly comprises a first motor and the second powertrain assembly comprises a second motor. The first motor and second motor are independent from one another and interchangeably coupled to the first axle or second axle. The vehicle can further include a first inverter and a second inverter. The first inverter is electrically coupled to the first motor and removably coupled to a first circuit in the vehicle. The second inverter is electrically coupled to the second motor and removably coupled to a second circuit in the vehicle. When the first motor is removed from the first axle and coupled to the second axle and the second motor is removed from the second axle and coupled to the first axle, the first inverter is removed from the first circuit and coupled to the second circuit and the second inverter is removed from the second circuit and coupled to the first circuit.
In another aspect, the first powertrain assembly includes a first drive assembly and the second powertrain assembly includes a second drive assembly. The first drive assembly and second drive assembly are independent and interchangeable with one another. The vehicle can further include a first motor and a second motor. The first motor is removably coupled to the first drive assembly and the second motor is removably coupled to the second drive assembly. As such, the first motor and second motor are interchangeably coupled to the first axle and second axle and the first drive assembly and second drive assembly are interchangeably coupled to the first axle and second axle. In addition, the vehicle can include a first inverter and a second inverter. The first inverter is electrically coupled to the first motor and removably coupled to a first circuit in the vehicle and the second inverter is electrically coupled to the second motor and removably coupled to a second circuit in the vehicle. In this aspect, when the first motor is removed from the first axle and coupled to the second axle and the second motor is removed from the second axle and coupled to the first axle, the first inverter is removed from the first circuit and coupled to the second circuit and the second inverter is removed from the second circuit and coupled to the first circuit.
In a different aspect, the first axle is a front axle and the second axle is a rear axle. Alternatively, the first axle is disposed on a left side of the vehicle and the second axle is disposed on a right side of the vehicle.
In a different embodiment, a method is provided for improving the durability of a powertrain assembly in a powered vehicle. The vehicle includes at least a first axle and a second axle and the powertrain assembly including a first powertrain and a second powertrain. The method includes removing the first powertrain from the first axle and the second powertrain from the second axle. The method further includes coupling the first powertrain to the second axle and the second powertrain to the first axle.
In one aspect, a motor or drive assembly of the first and/or second powertrain is removed from the vehicle. In a different aspect, the method includes interchangeably coupling the first powertrain to the first axle or second axle and interchangeably coupling the second powertrain to the first axle or second axle. In another aspect, the method includes monitoring a vehicle characteristic and comparing the vehicle characteristic to a threshold. After the vehicle characteristic exceeds the threshold, the first powertrain is removed from the first axle and coupled to the second axle and the second powertrain is removed from the second axle and coupled to the first axle. The vehicle characteristic can be hours of operation or miles. The method can also include switching a first inverter from a first circuit to a second circuit and switching a second inverter from the second circuit to the first circuit.
In another embodiment, a vehicle system includes a monitoring system for monitoring a vehicle characteristic, a first axle configured to power a first wheel, and a second axle configured to power a second wheel. The vehicle also includes a first powertrain system including a first motor, a first inverter, and a first drive assembly. The first motor is coupled to the first drive assembly and the first motor is electrically coupled to the first inverter. The vehicle further includes a second powertrain system including a second motor, a second inverter, and a second drive assembly. The second motor is coupled to the second drive assembly and the second motor is electrically coupled to the second inverter. The first motor is substantially the same as the second motor and the first drive assembly is substantially the same as the second drive assembly such that the first powertrain system and second powertrain system are interchangeably coupled to the first axle and second axle.
In one aspect, the first powertrain system is interchangeably coupled to one of the first axle or second axle in response to the vehicle characteristic monitored by the monitoring system. In another aspect, the second powertrain system is interchangeably coupled to one of the first axle or second axle in response to the vehicle characteristic monitored by the monitoring system. Alternatively, the first inverter and second inverter are interchangeably coupled to a first circuit and a second circuit in the vehicle system in response to the vehicle characteristic monitored by the monitoring system.
One advantage of the above-described embodiments is the ability to improve the durability and overall life the vehicle and its working components. Unlike conventional vehicles, these embodiments include motors, drive assemblies, and inverters that can be rotated from a front axle to a rear axle and vice versa. Alternatively, these components can be rotated from the left side of the vehicle to the right side of the vehicle and vice versa. This can be done after a predetermined number of miles or hours of operation has elapsed to reduce the wear on the components. Each of the components is independent and interchangeable with one another.
In addition, each powertrain assembly can include a motor, for example, that has one or more cast ramp on the bottom of its housing to simplify the assembly of the motor to an axle. The axle can include an axle housing to which the motor couples, and the cast ramp can slide along the interior of the housing to ease the assembly. This also simplifies the assembly and serviceability of the powertrain assembly because the motor or drive assembly can be serviced without removing an entire axle.
The above-mentioned aspects of the present invention and the manner of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein:
Corresponding reference numerals are used to indicate corresponding parts throughout the several views.
The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
Referring to
Each wheel is coupled to an axle assembly which produces and transfers power to the wheel. In this embodiment, there is a first axle 114 for driving the front wheel 106, a second axle 116 for driving the other front wheel 108, a third axle 118 for driving the rear wheel 110, and a fourth axle for driving the other rear wheel 112. As will be explained below, each axle includes an axle tube housing and flange for coupling to a power-producing apparatus. The power-producing device can be an engine, a motor, a battery, or any other similar device. If the power-producing apparatus is an engine, the engine can be diesel, hydraulic, pneumatic, or any other known engine. Alternatively, if the power-producing apparatus is a motor, the motor can be electric, hydraulic, or any other known motor. In one non-limiting example, the motor can be a switch reluctance motor. Alternatively, the motor can be a permanent magnet motor as well.
In this embodiment, each axle includes an electric motor for providing power to each wheel. For instance, the first axle 114 includes an axle housing 122, a motor 130, and a drive assembly 138. The motor 130 is coupled to a drive assembly 138 such that power is produced by the motor 130 and transferred to the drive assembly 138. The drive assembly 138 can include different gear sets, clutch assemblies, shafts, bearings, etc. for transferring the power produced by the motor 130 to the front wheel 106. The drive assembly 138 can be controlled to produce a different gear ratio depending on driving conditions and applications. The motor 130 is electrically coupled to a bank of inverters 146. The bank, or cabinet, of inverters 146 is disposed near the rear 104 of the vehicle 100. The bank of inverters 146 includes a plurality of inverters. Each motor in the vehicle includes an independent inverter. The first motor 130, for example, is electrically coupled to an inverter 150.
In the illustrated embodiment of
The generators 172, 174 can transfer mechanical engine power into electrical power and each generator inverter controls how much load each generator puts on the engine. It is desirable to keep the “bus” at a constant required voltage. The motor inverters then control the motors, which transfer this electrical energy back into mechanical. In other words, each motor depletes the “bus” whereas each generator recharges it. In this embodiment, the generators 172, 174 are driven by a generator/pump drive (not shown) which is coupled to the engine. One generator 172 drives the second motor 132 and third motor 134 and the other generator 174 drives the first motor 130 and fourth motor 136. In other embodiments, the generators can control any one of the motors.
As described above, the vehicle 100 includes a second axle 116 having an axle housing 124 and a second motor 132 which is coupled to a second drive assembly 140. The second drive assembly 140 is coupled to and provides power to drive the front wheel 108. The second motor 132 is electrically coupled to inverter 148 via circuit 160. The circuit 160 can include wires and other electric components for operating the motor 132.
The third axle 118 also includes an axle housing 126 and a third motor 134 which is coupled to a third drive assembly 142. The third drive assembly 142 is coupled to and provides power to the rear wheel 110. The third motor 134 is electrically coupled to the inverter 158 via a circuit 166. Similarly, the fourth axle 120 can include an axle housing 128 and a fourth motor 136 which is coupled to a fourth drive assembly 144. The fourth drive assembly 144 is coupled to and provides power to the rear wheel 112. The fourth motor 136 is electrically coupled to the inverter 156 via a circuit 164.
Referring to
The motor 130 includes a motor housing 200, a plurality of hoist connections 206, a plurality of cast feet 204, and a plurality of cast ramps 218. The design of the motor housing 200 is advantageous over conventional motor housings because the manner in which the motor 130 is coupled to the axle is simplified. In many conventional motors, the housing is substantially round and cannot be easily guided into connection with the axle. Therefore, to connect a conventional motor housing to an axle tube housing, for example, a counterweight was required on the side of the motor opposite the axle tube housing to balance the weight. Otherwise, the hoist or other tool used to connect the motor to the axle would be unable to make the connection. Alternatively, a specially designed hoist or tool would be required to connect the motor to the axle. In some instances, a conventional drive assembly is first connected to the conventional motor before the assembly could be connected to the axle. This often increases the amount of time for assembling and disassembling the axle. In some conventional axles, the entire axle has to be dropped to make a repair to the conventional motor or drive assembly.
Many of these disadvantages with conventional motors are overcome by the motor housing 200. The plurality of cast feet 204 and cast ramps 218 allow the motor housing 200 to slide inside the axle tube housing 202 to simplify assembly and disassembly. The plurality of cast feet 204 is disposed along the bottom side of the motor housing 200 from the front to the rear of the housing 200. The plurality of cast ramps 218 are configured at an angle near the front of the motor 130 to achieve a simpler connection to the axle tube housing 202. In addition, dowel pins (not shown) or the like can be used to align the motor housing 200 with the axle tube housing 202 during assembly. The motor housing 200 includes slots or openings (not shown) through which dowel pins can be inserted for alignment.
In
Once the motor 130 is coupled to the axle 114, the drive assembly 138 can be coupled to the motor 130. To do so, the spindle 212 is coupled to the axle tube flange 210. Although not shown, the spindle 212 can include a small groove or notch which engages a seal or o-ring disposed along the diameter of the motor plate 208. The motor plate 208 can locate the seal such that when the spindle 212 is coupled to the flange 210, a face seal is formed therebetween. In addition, the motor plate 208 can help pilot the spindle 212 to the motor 130 to minimize misalignment therebetween. Once the spindle 212 is coupled to the flange 210, the drive housing 214 can be coupled to the spindle 214.
This layout/configuration allows for better serviceability of the vehicle. For instance, if the drive assembly 138 needs repaired, the drive assembly 138 can be disengaged from the motor 130 without having to either drop the entire axle 114 from the vehicle or remove the motor 130 in addition to the drive assembly 138. Thus, the manner in which the motor 130 and drive assembly 138 can be coupled to the axle 114 allows for improved serviceability and better overall vehicle productivity (due to less downtime).
Another advantage of the previously described embodiments is the interchangeability of the motors, drive assemblies, and inverters. A vehicle may include different axles and connections thereto, particularly when the vehicle includes a fixed, front frame and an oscillating, rear frame. However, in the previously described embodiments, the motors and drive assemblies are independent from one another but are substantially the same. As such, any one of the motors can be coupled to any one of the axles. Likewise, any one of the drive assemblies can be coupled to any one of the axles.
In many conventional vehicles, the components disposed near the front of the vehicle can be exposed to greater loads, torques, or speeds and therefore wear more quickly than those disposed near the rear. Also, depending on vehicle application, some vehicles may turn to the left or right more than in the other direction. As such, additional load or torque can cause components to wear more quickly on a particular side of the vehicle. In most conventional vehicles, however, axles, motors, drive assemblies, etc. are different from one another and especially from the front side of the vehicle compared to the rear. For example, axles can have different ratios and the like and thus require a certain motor or drive assembly due to the connections thereto.
In the embodiment shown in
The first motor 312, second motor 316, third motor 320, and fourth motor 324 are each independent from one another. However, each is substantially the same and therefore interchangeable with each other. For instance, the first motor 312 and second motor 316 can be rotated from the front 300 of the vehicle to the rear 302 (indicated by arrow 330). Likewise, the third motor 320 and fourth motor 324 can be rotated from the rear 302 of the vehicle to the front 300 (indicated by arrow 332). Advantageously, it does not matter to which axle the motors are coupled to. For example, after the rotation, the first motor 312 can be coupled to either the third axle 308 or fourth axle 310. The second motor 316 can also be coupled to the third axle 308 or fourth axle 310. Similarly, the third motor 320 and fourth motor 324 can be coupled to either the first axle 304 or second axle 306.
In the above example, the motors can be rotated and coupled to any of the drive assemblies of each axle. However, it is also possible to rotate the drive assemblies to different axles. The first drive assembly 314 and second drive assembly 318 can be rotated from the front 300 to the rear 302 and coupled to the third axle 308 or fourth axle 310. Likewise, the third drive assembly 322 and fourth drive assembly 326 can be rotated from the rear 302 of the vehicle to the front 300 can coupled to the first axle 304 or second axle 306.
In both of the previous examples, either the motor or drive assembly was rotated. However, it is further possible to rotate both the first motor 312 and first drive assembly 314 from the first axle 304 to the second axle 306, third axle 308, or fourth axle 310. Similarly, the second motor 316 and second drive assembly 318 can both be rotated to the first axle 304, third axle 308, or fourth axle 310. The same can be true for the third motor 320 and third drive assembly 322 and the fourth motor 324 and fourth drive assembly 326.
Referring also to
In the exemplary embodiment shown in
Each inverter can be rotated whenever the motor to which it is electrically coupled is rotated. Thus, if the first motor 312 is rotated with the second motor 316 such that the first motor 312 is coupled to the second axle 306 and the second motor 316 is coupled to the first axle 304, the first inverter 400 is removed from the first circuit 416 and coupled to the second circuit 418. Likewise, the second inverter 402 is removed from the second circuit 418 and coupled to the first circuit 416. The rotation or switching of inverters is indicated by arrow 412. In addition, if the third motor 320 is rotated to the fourth axle 310 and the fourth motor 324 is rotated to the third axle 308, the third inverter 404 is rotated to the fourth circuit 422 and the fourth inverter 406 is rotated to the third circuit 420. This rotation is indicated by arrow 414. Therefore, each inverter remains with its corresponding motor after each rotation.
The present disclosure further contemplates a monitoring system in a vehicle. The monitoring system, similar to the controller 170 in
Test results of rotating components can improve the durability of these components by up to 50%. In one example, a drive assembly required a rebuild after 18,000 hours of operation. However, a different drive assembly was rotated after a certain number of hours of operation and this drive assembly did not require a rebuild until almost 27,000 hours. The gears and bearings of the drive assembly showed an increase in durability and overall life due to the rotation. The ability to monitor mileage or hours of operation, for example, can trigger the timing for rotation of components.
The embodiments described above refer to vehicles that include four axles. However, the present disclosure is intended for vehicles having fewer or more than four axles.
While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
