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  • Ford F150 EV Range Extender Patent

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    Simon Alvarez
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    138K vizualizări12 pagini

    Ford F150 EV Range Extender Patent

    Încărcat de

    Simon Alvarez
    patent

    Drepturi de autor:

    © All Rights Reserved
    Descărcați ca PDF sau citiți online pe Scribd
    Indicator pentru conținut neadecvat
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    (2) oy om ~ my os) 68) United States Patent Caliskan et al. ELECTRIFIED VEHICLES WITH REMOVABLE AND INTERCHANGEABLE, RANGE EXTENDING GENERATORS, (C, Dearborn, MI(US) Inventors: Avi Caliskan, Canton, Mi (US); John Jaranson, Dearborn, MI (US): Peter A. Friedman, Ann Arbor. MI (US) Arnold Kadiu, Dearborn, MI (US) Assignee: FORD GLOBAL TECHNOLO (C, Dearborn, MI(US) Notice: Subject to any disclaimer, the teem ofthis pateat is extended of adjusted under 35 USC. 154(b) by 8 days. Appl. Now 18/963,202 Filed: Apr 26, 2018 ‘ioe Publication Data $ 201910329687 AL Oct. 31, 2019 Im. Cl, BoOK 800 (2006.01) BOOL S3/18 (2019.01) B60 S061 (201901) u fad BOOL. $314 (2019.02); BOOK 8/00 (QO13.01): AOL S061 (2019.02), BOOL 2200036 2013.01) Field of Clasitcat cre B6OL. 11/1809) ‘See application file for compte search history. Search US010773602B2 US 10,773,602 B2 ep. 15, 2020 (10) Patent No.: (4s) Date of Patent: 66) References Cited US. PATENT DOCUMENTS. 571.949 B2 62003 Bums IV eal Gs9o041 27003 Toll 1065.31 7514803 B2* 42009 Wilks BeOL 111822 1168 SS98KST BL* 72016 Theobald Book 1600 Sustisas B2* 102016 Caldeies Beal 30046 aoopotesios AL 102002 Brot BOK 9 106 20060000650 A1* 1/2006 Hughey B6OK 6/36 180065.25 1s065.21 20110225539 A1* 92011 Hass GOK 646 (Continved) POREIGN PATENT DOCUMENTS De Primary Examiner’ Assistant Examiner (4) Attornes, Agent or Firm Carlson, Gaskey & Olds on ABSTRACT Tie disclosure details electrified vehicles that are equipped with removable generators for inereasing the electric rmige of the vehicles. An exemplary electrified vehicle includes fargo space, sich asa tack bad, and generator removably positioned within the eargo space, The generator is adapted fo selectively supply power for ether charging battery peek ofthe eletrifed vehicle or for propelling one or more Vehicle drive wheels. Ia some embodiments the generator is shaped lke, and therefore disguised as, a toolbox 16 Claims, 5 Drawing Sheets 10-2015-005318 AL 102016 James A Shriver I James J Trigas David B. Kelley —[ inecer } aching Electie 257 Graing w US 10,773,602 B2 Page 2 66) References Cited USS. PATENT DOCUMENTS. 20150015065 AL* 1/2015 Bruns B01. 300 307108 2O1S210182 AL* 7/2015. Adkus B60 11 1809| 1806s 248 20160000232 AL 2016. Baday * cited by examiner US 10,773,602 B2 Sheet 1 of § Sep. 15, 2020 U.S. Patent bold BENY og Z we}shg Buibueyo, g@ |S¢ Se auiyoey 9149913 foo yoeg Aiayeg v% Jojes0ued) 7 WS U.S. Patent Sep. 15, 2020 Sheet 2 of 5 US 10,773,602 B2 FIG. 2 U.S. Patent Sep. 15, 2020 Sheet 3 of 5 US 10,773,602 B2 ws . RY 35 H 8B £ ee mo By 3B Ny e 7 | 2 a ~~ °o ira a = 8 ® RY & 5 3 £ Kc z £ 69 Ite U.S. Patent Sep. 15, 2020 Sheet 4 of 5 US 10,773,602 B2 FIG. 5 US 10,773,602 B2 Sheet 5 of 5 Sep. 15, 2020 U.S. Patent 6 "Old ‘S}98uM euIyoRW) | wed | aaaee waysis anud owe Ksayeg soyeleues josjuog) 7 0 7 8 yh % * 66 8Old * Z ~~] JORIBUAD }---, Sas Sjeauy BUIYORW) +---2 — weysks jo anu ouyo9ig f=~~» | JoqU05) ee } at vt Aenea 66 ( oo \ z yOL US 10,773,602 B2 1 ELECTRIFIED VEHICLES WITH REMOVABLE AND INTERCHANGEABLE, RANGE EXTENDING GENERATORS, ‘TECHNICAL FIELD ‘This disclosure dotils elected vehicles that are ‘equipped with removable generators for inereasing the elee> tric range of the vehicles BACKGROUND The desire to reduce automotive fel consumption and ‘emissions has boen well dacuented, Therefore clostified Ychicles are being developed that reduce or completely ‘eliminate reliance on internal combustion engines. In gen feral, eloctified vehicles differ from conventional motor ‘Vehicles because they are selectively driven by one or more battery powered electric machines. Conventional motor vehicles, by contrast, rely exclusively on the intemal com bution engine to propel the vehicle. ‘A igh voltage battery pack typically powers the electric machines and other electrical loads of the electrified vehicle ‘The high voltage batery pack provides a limited amount of clectric-only driving singe. Some customers desire the abil- jty to add addidonal electric-only range to their elected vehicles. SUMMARY, Anelectrifed vehicle according to an exemplary aspect of the present disclosure includes, among other things, a drive wheel, battery pack, a cargo space, and) a generator Femovahly positioned within the cargo space and adapted to selectively output power for ether changing the battery pack ‘or propelling the drive wheel, The generator is shaped like ‘toolbox, TIn-a farther non-limiting embodiment of the foregoing ‘lecitiod vehicle, the electrified vehicle is 9 pickup tuck, Ina further nonlimited embodiment of either of the ‘foregoing eletifed vehicles, the cargo space is established by a truck bed of the pickup track, In a further non-limited embodiment of any of the Fore= oing electrified vehicles, at least a portion ofa bottom wall Of the generator is spaced a distance above a floor of the ‘cargo spc. Tn Turthee non-limited embodiment of any of the Fore= poing electrified vehicles, the generator includes an enclo- sure that Houses an engine and a fuel tank Tn a further non-limted embodiment of any of the Fore= poing elected vehicles, the enclosure futher houses an ‘exhaust system and electronics of the generator. In a further non-limited embodiment of any of the Fore poing electrified vehicles, the vehicle includes a connection system for electrically connecting the generator toa voltage bus of the eleczfied vehicle Tn a further non-limitad embodiment of any of the fore= oing electrified Vehicles, the consoction system includes @ Vehicle-side connector and a generaor-side connector. Ina further non-limited embodiment of aay of the Fore= oing electrified vehicles, the vehicle-side connector is recessed into a Moor of the cargo space and the generator side connector protrades from a bottom wall ofthe genera- ‘In a further non-limitad embodiment of any of the fore ping electrified vehicles, the vehicle-side connector is a {emale connector and the battery-side connector is @ male ‘connector. 0 o 2 4 further noa-limited embodiment of any of the fore= soing electrified vehicles, the generator includes locating stud received within openings ofthe eargo space In a further noa-limited embodiment of any of the Fore: soing electrified vehicles, the generator is interchangeable with a second generator that includes a different poser capacity compared to the generator. Ina further noo-limited embodiment of any of the Fore- going electrified vehicles, the generator is connected in series relative to the battery pack. Ina further noa-limited embodiment of any of the Fore: going electrified vehicles, a contol system is configured 10 ‘canto the power outputted by cach of the batery pack and the generator during @ drive eyee. ‘In a further non-limited embodiment of any of the fore ing electrified vehicles, human mochine interface is in ‘communication with the control system and configured 10 receive an operating mode input for controlling the gener tor during the drive eyele A method acconting (0 another exemplary aspect of the present disclose includes, among other things, positioning 4 gencrator within a cango space of an electrified vehicle, ‘The generator is disguised as @ toolbox. Power from the sdenertor may be output for either propelling a whee! ofthe lecirifed vehicle or charging a batery puck of the elets- fied vehicle, Tn a further non-limiting embodiment of the foregoing ‘method te method includes outputing the power from the szencmitor and power from the batery pack ia parallel In a further nou-limiting embodiment of either of the {foregoing methods, outputting the power from the generator is only performed when a state of charge ofthe battery pack falls below a threshold level, In a further non-limiting embodiment of any of the foregoing methods, positioning the generator within the cargo space includes Connecting a vehiele-sde connector to a generator-sde connector. Tn a farther non-limiting embodiment of any of the foregoing methods, the method includes removing the gen- erator from the eargo space and replacing the generator with ‘a second generator that has a dilferent power capacity than the generator ‘The embodiments, examples and alternatives of the pre= ceding paragraphs, the claims, or the following description ‘and drawings, including. any of their various aspects or respective individual feaues, may be taken independenty fr in any combination, Features deseribed in connection with one embodiment are applicable to all embodiments, unless such features are incompsle "The various features and advantages of this disclosure will become apparent to those skilled inthe art from the following detailed description. The drawings that accom ppany the detailed description can be brielly described as {allows BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 schematically illustrates 4 powertrain of an elee- trifle vehicle FIG. 2 illustrates an electfied vehiele that may employ the powertrain of FIG. 1 FIG. 3 schematically illustrates the nterchangeability of diffrent sized generators that may be emplayed by the electrified vehicle of FIG. 2 FIG. ilstmtes a generator of the electrified vehicle of FIG. 2, US 10,773,602 B2 3 FIG. 5 illustrates a connection system for connecting a enerator 1 a voltage bus of an electrified vehicle FIG. 6 illustrates a generatorsde connector of the con- nection system of FIG. 5. FIG, 7 illustrates a vebicle-side conaector of the connec: tion system of FIG. 5. IG, 8 ilustates an eletric drive system aovording 0 a first embodiment ofthis disclosure. PIG, 9ilusintes an electric drive system aocording io & second embodiment ofthis disclosure DETAILED DESCRIPTION ‘This disclosure dotils clectified vehicles that are ‘equipped with removable generators fr increasing the elec tric range of the vehicles. An exemplary electrified vehicle includes a cargo space, sch as a trck bed, andl a generator removably positioned within the cargo space. The generator is adapted to selectively supply power for ether charging & buttery pack of the electrified vehile or for propelling one ‘or more vehicle drive wheels. In some embodiments, the enerator is shaped like, and therefore disguised as, a toolbox. These and other features are discussed in grester detail inthe following paragraphs of this detailed descrip FIG. 1 schematically Ulustrtes a powertrain 10 of a ‘electrified vehiele 12. In an embodiment, the electrified vehicle 12 is batery electric vehicle (BEV) that is pro- pelle solely through electric power, such as by an electric machine M4, without any assistance from an intemal com bastion engine. The electric machine 1d roceives electrical power and provides a rotational output poser. [aan embodi- ment, the electric machine 14 isan elecirie motor. The electric machine 14 may be connected to a pearbox. 16 for adjusting the output torgue and speed ofthe electric machine 14 by a predetermined gear ratio, The gearbox 16 js connected ta set of drive wheels 18 by an output shaft 20. A voliage bus 22 eloctically’ connects the electric Iachine 14 to a battery pack 24 thromgh an inverter 26, The ‘eleciic machine 1, the gearbox 16, and the inverter 26 may be collectively refered to asa transmission 28 The battery pack 24 is an exemplary electrified vehicle butiery. The battery pack 24 may be a high voliage traction battery pack that includes @ plurality of battery arrays 28 (Ge, hattery assemblies or groupings of battery eels) ‘capable of outputting electrical power to operate the electric machine 14 andor other eletrcal loads of the electrified vehicle 12 for providing the power necessary to propel the wheels 18. Other types of enemy storage devices andor ‘output devices ean also be used to electrically power the ‘lecrfied vehicle 12 The electrified vehicle 12 is also be equipped with a ‘charging system 30 for charging the energy storage devices (eae, battery cells) of the battery pack 24. The charging system 30 ean be connected to an extemal power source for receiving nd distributing power received from the extemal power source to the batery pack 24 The electrified vehicle 12 may be operable to travel over 4 specific distance prior (o energy depletion of the battery pack 24, which may lead to operator range anxiety. Avcord- ingly, the electrified vehicle 12 may additionally be ‘equipped witha generator 84 for inereasing the travel range ‘of the eloctifed vehicle 12, Like the battery pack 24, the ‘generator §4 may be operably connected to the electric machine 14 through the inverter 26 over the vollage bus 22. ‘The generator $4 may also be connected either in parallel oF Jn series relative to the battery pack 24. As discussed i 0 o 4 areater detail below, the generator $4 may be a gasoline driven generator tht is removable and interchangeable ‘The powertrain 10 shows in FG. 1 is highly schematic and is not intended to limit this disclosure. Various addi- tional components could altematively or additionally be employed hy the powertmin 10 within the scope of this iselosure. In adltion, the teachings ofthis disclosure may be incorporated into any type of electrified vehicle, inciud- ‘ng but not limited to trucks, sport lity vehicles, ears, ee FIG, 2 illustrates an electeified vehicle 12 that may employ the powertrain 10 shown in FIG, 1, oF any other clectrified poweririn. In an embodiment, the elevfied vehicle 12 i «pickup track. Although a specific component relationship is lustrited in the figures ofthis diselostre, the illstations are not intended to limit this disclosure. The placement and orientation ofthe various components of the lectrified vehicle 12 are shown schematically and could vary within the seope of this disclosure, In addition, the various figures aecompanying this disclosure are not ncees- sarily to scale, and some features may be exaggerated oF ‘minimized to show certain details o a parila component. “The clectified vehicle 12 includes a trick bed 56 that establishes a cargo space for storing and hauling eargo at a reat location of the electrified vehicle 12. The truck bed 56 is wenerally rearward of a passenger eabin 58 of the elee- trifle vehicle 12 and includes a floor 60 extending between pair of longitudinally extending side walls 62, a laterally extending front wall 64, and tailgate 66. The tailgate 66 is moveable between a closed position (not shown) and deployed or open position. When in th closed position, the tailgate 66 generally encloses an end ofthe ruck bed $6 that js opposite from the front wall 64 to prevent cargo from sliding out of the teuck bed 56, When ia the open position, the tailgate 66 is generally horizontal and Unts parallel to saround level suc that cargo ean be loaded onto or unloaded from the trick bed 6 ‘The generator $4 may be positioned within the trek bed 56, such a near the front wall 64. In an embodiment, the generator $4 i shaped Tike, and therefore disguised as, a toolbox. Disguising the generator $4 as a toolbox gives the ceustomer the option to add addtional electric range to the clecirfied vehicle 12 without sacrificing any more cargo space than would be taken up by a traditional saddle style ‘tuck bed toolbox. In te installed position, at least a portion ‘of a bottom wall 84 of the generator $4 may be spaced a ‘stance D above the Moor 60 of the truck bed $6. Therefore, cargo may be slid underneath the generator $4 even when the electrified vehicle 12 is equipped wih the generator 84 Referring to FIGS. 2-3, the generator 54 may be remov- able from the truck bed $6 and interchanged with different sized generators fo accommodate the specific enerzy needs of the eustomerluser. In such @ modular design, the eu tomeriuser could employ a small (eg. $ kW with 5 gallon capacity), medium (eg, $ kW with 10 gallon capacity), oF large (¢., 15 kW with 20 gallon capacity) generator §4 ‘within the tuck bed $6, The small generator $4 may occupy 8 fist amount of space SI of the truck bed 56, the medi snenerator $4 may occupy a second amount of space S2 ofthe {ruck bed $6, and the lage generator 54 may occupy a third amount of space $3 of the tuck bed $6, The second amount fof space SP is greater than the first amount of space SI, and the third amount of space 83 is greater than the second amount of space $2. Incrsasing the travel range of the electrified vehicle 12, such as by using a laner-sized en- femtor $4, may therefore reduce the amount of available cargo space within the eletrifed vehiele 12, US 10,773,602 B2 5 FIG, 4 illustrates additional feanures of the exemplary enerator $4 of FIG. 2. FIG. isa top, eross-sectional view ‘of the generator 4 fr visualizing is internal contents. Tn aa ‘embodiment, the generator 84 inehides an enelostre 68 that houses an engine 70 or other power souree, a fe tank 72, fan exhaust system 74, and various electronics 76. Other ‘components could adkltionally be housed inside the enclo~ sre 68 within the scape of this disclosure. The enclosure 68 may be shaped like a toolbox in onder to disguise the generator 4 as a truck bed toolbox. The ‘enclosure 68 may be constructed of polymer-based mate Fial, « metallic material, or a combination of polymer-based ‘and metallic materials, Hossever, the actual size, shape, and material make-up of the enclosure 68 are not intended t0 limit this disclosure, The engine 70 is the main power source of the generator 54. During operation, the engine 70 creates mechanical ‘energy that is converted into electical energy that can be ‘outputted by the generator 84. The operating specifications ‘of the engine 70 are design specific and can be selected 10 provide @ desired electrical energy out ‘The fuel tank 72 stores fel for powering the engine 70 JInan embodiment, the fue s gasoline. However, other fuels ‘are also contemplated within the seope of this disclosure, ‘including but not limited to, diesel, propane, natural g35, oF ‘any combination ofthese or other fuels. ‘he exliaust system 74 is adapted to remove excess heat ‘and exhaust gases fom the generator 84, sue as those that may be generated by the engine 70, The exhatist system 74 may include fans, vents, pumps, heat exchangers, ete “The electronics 76 generally contol the operation of the various components ofthe generator $4. In an embodiment the electronics 76 inchide the necessary hardware and sole are for controlling the components ofthe generator $4 and {or achieving bi-lrectional communication with the com onents of the powertrain 10 of the electrified vehicle 12. ‘The elecironies 76 may inckude various contol units, vol age regulators, switches, ot “The generator 84 could optionally include one or more power outlets 32. The power outlets 32 may be avcessible fom an exterior ofthe enclosure 68. The owneritser af the ‘locfied vehicle 12 may plug. any tools or other electrical socessories into the power outlets 32 in order to power these tools using energy provided by the generator $4, Thus, ia ‘addition to providing power to the powertrain 10, the generator $4 could adkltionally power various accessory vices, FIG. 5, wth continued reforence to FIGS. 1, 2,3, and 4, ‘ustates a connection system 78 for electrically connecting the generator $4 to the voltage bus 22 of the electrified vehicle 12. The connection system 78 may include a vehicle- side connector 80 and a generatorside connector 82. In an ‘embodiment, Uke vehicleside connector 80 is rigidly dis posed within the floor 60 of the truck bed $6, and the enerator-sde connector 82 is rigidly disposed in bottom ‘wall 84 of the enclosure 68 ofthe generator 84. In another ‘embodiment, the vehicle-side connector 80 is a female ‘connector and the generator-side connector 82 is @ male ‘connector, However, aa allemative contiguration is also ‘contemplated in which the vehicleside eonnector 80 i the male connector and the generatorside connector 82 is the female connector. The generatr-side connector 82 may be phgget into the vehice-side connector 80 to connect the ‘Benerator S440 the voltage bus 22 ‘The connection system 78 may additionally include one ‘or more locating features for aligning the gencrator-side ‘connector 82 with the vehicleside connector 80 a the 0 o 6 szenerator $4 is moved into positon within the truck bed $6 In an embodiment, the enclosure 68 of the generator §4 includes locating. studs 86 that protude inwardly Irom ‘mounting Ranges 88 located at each opposing side of the enclosure 68, The locating studs 86 may be received within ‘openings 90 formed in the side walls 62 ofthe track bed 56 The locating studs 86 may be slid into the openings 90 to align the generatorside connector 82 with the vehicleside connector 80. Therefore, as the generator 4 is. moved ‘urther toward the loor 60 during installation, the penerator- side connector 82 will be properly positioned for engaging the vehicle side connector 80. FIG, 6 illustrates the generatorside connector 82 of the connection system 78, The generator-side connector 82 may slightly protrude outwardly from the bottom wall 84 of the enclosure 68. The generatorside connector 82 may include Jow voltage connection ports 92 and high voliage connection ports 94. Of course, the generator-side connector 82 could embody other configurations within the scope of this dis- closure, “The high voltage connection ports 94 allow the generator 4 10 be connected with the battery pack 24 andlor the inverter 26. The low voltage ennncction ports 92 allow for CAN communication between the generator S4 and the battery pack 24, the inverter 26, or other components ofthe powertrain 10. ‘he generator-sde connector 82 may additionally include 4 Tock setuator 96, The lock actuator 96 is configured +o prevent removal ofthe gencrator-side connector 82 from the ‘ehicle-side connector 80 while the electrified vehicle 12 is ‘operating (Le. ignition is tumed ON), PIG, 7 illustrates the Vehicle-side connector 80 of the connection system 78, The vehicle-sde canncetor 80 may be slightly recessed into the foor 60 ofthe truck bed $6. The connection ports of the vehicle-side connector 80 may generally mirror those of the generctorside connector 82 and may include low voliage connection ports 98, high voltage connection ports 100, and a Toek actuator 102, The battery-rce connector #2 could embody other configure ‘ions within the scope of this disclosure, "The battery pack 24 andthe generator $4 ofthe clctified vehicle 12 may be controlled to simultaneously utp power for powering the cletric machine 14 of the electrified Vehicle 12. The elecsic machine 14 may then output torque Tor propelling the one or more drive wheels 18 of the lectifed vehicle 12 ‘As showin in PIG. 8, the battery pack 24 and the generator ‘34 can be controled bya contol system 99 to provide power to the electric machine 14 in parallel with one another. The ‘control system 99 may inelude hardware, software, or both, {orperfonming the necessary contro factions for outputting power from the battery pack 24 and the generator $4 Althougls shown as a single hardware device, the contol system 99 could inclade multiple controllers in the form of multiple hardware devices, or multiple software controllers within one or more hardware devices. In addition, the control system 99 may include one or more processing units and non-iransitory memory for executing te various contol Sategies and modes ofthe electrified vehicle 12 ‘The control system 99 may be programmed to control the ‘amount of power outputted by each of the battery pack 24 fand the generator $4 during each operating mode of the ‘lectifed vehicle 12, Inan embodiment, the contol system 9 automatically commands the generator $4 "ON? if a power demand of the electrified vehicle 12 exceeds a predefined power threshold. In ancther embodiment, the ‘control system 99 automatically commands the generator $4 US 10,773,602 B2 1 “ON'ifthe state of charge (SOC) ofthe battery pack 26 falls below a predefined threshold In yet another embodiment, the contol system 99 is programmed to contol the power outputted by each of the battery pack 24 and the generator $4 during a given drive ‘eyele based on inputs from the eustomerivser. Par example, the clectified vehicle 12 may inclode a human machine interface (HMI) 104 that is in electrical communication with the conto! system 99. The HMI system 104 may be located within the passenger cabin 58 of the cletrfied vehicle 12 and may include one of more user interfaces 106. The ‘customev/user may interoet with each user interface 106 via ‘ touch sereen, tate butions audible speech, speech syn= thesis, ete. The customeriuser can either enter information Jno the user interface 106, oF the user interface 106 can

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