Configurable, modular vehicle on common chassis platform, and associated systems and methods

A configurable, modular vehicle on common chassis platform, and associated systems and methods are disclosed herein. In one embodiment, a configurable modular vehicle includes: a chassis, a power plant module configured to generate electrical energy, and a drive train module. The drive train module includes: at least one traction motor configured to receive electrical energy from the power plant module, a transmission configured to transfer torque from the traction motor to a drive axle, and the drive axle configured to transfer torque to drive wheels, and a control system module configured to control components of the power plant module and the drive train module. The interfaces of the power plant module and the drive train module are predefined, and different types of the power plant modules and the drive train modules are interchangeable within their respective predefined interfaces.

BACKGROUND

Conventional trucks are designed for specific transportation purposes, for example, short range delivery by a box truck, transporting and mixing concrete by a mixer truck, hauling large loads to large distances with Class 8 tractor trucks, and so on. The engine and transmission for a particular truck is selected based on its size, load limits, hauling distance requirements, and other requirements. When a truck is redesigned, or an existing truck is updated, the process starts essentially from scratch by selecting or designing chassis, engine, transmission, auxiliary components, cabin, and so on. These components are then arranged and integrated into a completed truck per customer requirements.

FIG. 1is a side plan view of a tractor-trailer combination in accordance with conventional technology. The tractor-trailer combination includes a tractor or truck10having a so-called fifth wheel by which a box-like semi-trailer20may be attached for transporting cargo. In operation, torque is transferred from the engine/transmission to rear wheels19to drive the truck/trailer combination. The illustrated truck10also includes a cab12and an attached sleeper14.

FIG. 2is a top view of the tractor10in accordance with an embodiment of the present technology. With the conventional tractor10, the engine compartment houses an engine16that is coupled to a transmission15for transmitting power to the drive wheels (not shown). When a tractor is redesigned or a new tractor is designed from scratch, the space within the engine compartment (and other spaces within the chassis of the tractor) are rearranged and populated with the components of the tractor. For example, a new engine may be mated to a new transmission. Depending on the size of the new engine and transmission, other components will be arranged within the available space in the engine compartment and other spaces of the tractor.

Some more recent truck designs use hybrid power plants with an internal combustion engine and a stack of batteries. These trucks are generally more energy efficient under some use conditions (e.g., a stop-and-go driving). However, the design flow for hybrid trucks generally follows the established process of designing conventional trucks. That is, truck components (engine, batteries, transmission, auxiliary systems, etc.) are either selected or designed from scratch, and then arranged within a chassis (typically newly designed), with little or no design efficiency improvements or the corresponding cost savings.

Accordingly, there remains a need for cost- and space-effective truck designs that aim to address one or more problems of prior art systems.

SUMMARY

In one embodiment, a configurable modular vehicle includes: a chassis; a power plant module configured to generate electrical energy; and a drive train module. The drive train module includes: at least one traction motor configured to receive electrical energy from the power plant module, a transmission configured to transfer torque from the traction motor to a drive axle, and the drive axle configured to transfer torque to drive wheels. The configurable modular vehicle also includes a control system module configured to control components of the power plant module and the drive train module. Interfaces of the power plant module and the drive train module are predefined. Different types of the power plant modules and the drive train modules are interchangeable within their respective predefined interfaces.

In one aspect, the power plant module includes: an engine and a generator configured to receive the torque from the engine. The generator is electrically connected with the at least one traction motor of the drive train module. In one aspect, the power plant module further includes an engine gear box connected with the engine and the generator, where the engine gear box is configured to transfer torque from the engine to the generator.

In one aspect, the engine is selected from a group consisting of a diesel engine, a gas engine, a compressed gas engine, a gas turbine, and a fuel cell engine. In another aspect, the at least one traction motor is an electromotor electrically connected to a generator of the power plant module. In one aspect, the at least one traction motor is a first traction motor, and the configurable modular vehicle includes a second traction motor that is electrically connected to the generator of the power plant module.

In one aspect, the control system module includes rechargeable batteries. In another aspect, the at least one traction motor of the drive train module receives electrical energy at least in part from the rechargeable batteries. In one aspect, the power plant module includes an electrical charger configured to charge the rechargeable batteries. In another aspect, the control systems module includes an energy management controller configured to manage an accessory package, power electronics and the rechargeable batteries of the control systems module.

In one aspect, the configurable modular vehicle includes at least one support subsystems module having a fuel tank, an air compressor, at least one air tank, an exhaust subsystem, and an air intake subsystem. In another aspect, the control system module has predefined interfaces, and wherein different types of the control system modules are interchangeable within their predefined interfaces. In one aspect, the vehicle is a Class 8 truck.

In one embodiment, a method for designing a configurable modular vehicle includes: defining interfaces for a power plant module, a drive train module, and a control system module; defining elements of the power plant module, the drive train module, and the control system module; and interfacing the modules at their corresponding shared interfaces. The power plant module is configured to generate electrical energy and to provide electrical energy to the drive train module. The drive train module is configured to provide torque from at least one traction motor to a drive axle, and the control system module is configured to control components of the power plant module and the drive train module.

In one aspect, the power plant module is a first power plant module, and the method further includes replacing the first power plant module with a second power plant module, where the first power plant module and the second power plant module include different types of engines.

In one aspect, the power plant module comprises: an engine; an engine gear box connected with the engine; and a generator mechanically connected with the engine gear box and electrically connected with the at least one traction motor of the drive train module. The engine is selected from a group consisting of a diesel engine, a gas engine, a compressed gas engine, a gas turbine, and a fuel cell engine.

In one aspect, the drive train module includes: at least one traction motor connected to a transmission; the transmission configured to transfer torque from the traction motor to a drive axle; and the drive axle configured to transfer torque to drive wheels.

In another aspect, the control system module is configured to control components of the power plant module and the drive train module. In one aspect, the control system module includes rechargeable batteries. In one aspect, the power plant module includes an electrical charger configured to charge the rechargeable batteries. In another aspect, at least one traction motor of the drive train module receives electrical energy at least in part from the rechargeable batteries.

DETAILED DESCRIPTION

While several embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the claimed subject matter. Briefly, the inventive technology is directed to a modular design of configurable vehicles, for example, trucks. In some embodiments, designated spaces are allocated to different components (modules) of the truck, for example, a power plant module, a drive train module, a control system module, and an auxiliary systems module. The interfaces between these modules may be defined and fixed from one truck design to another. For example, electrical power cables connecting an electromotor of the drive train module to a generator or batteries of the power plant module may have a predefined size and location for all subsequently designed modular trucks. Therefore, different drive train modules (e.g., diesel engine with an electrical generator, gas engine with an electrical generator, a bank of rechargeable batteries) can be deployed in different modularly designed trucks as a drop-in option without having to redesign the drive train module or to change its interface to other parts of the truck. When used to design commercial trucks, the modular design results in a configurable “plug and play” commercial truck that can use different combinations of power plants, drive trains, auxiliaries, number of drive wheels, and so on. Therefore, the design process is simplified and shortened, resulting in a less expensive truck that is faster to market.

FIG. 3is a schematic view of a modular vehicle (e.g., truck or tractor) in accordance with an embodiment of the present technology. The illustrated modular vehicle includes several modules arranged around chassis600: power plant module100, a drive train module200, support subsystem modules300and400, and an energy module500.

In some embodiments, the power plant module100includes an engine110, an engine gearbox120and a generator130. Some examples of the engine110include a diesel engine, a compressed gas engine, a fuel cell engine, a turbine, and a gas engine. In operation, the engine110generates torque that powers the engine gearbox120which adjusts rotations per minute (rpm) of its output axle to match the expected rpm at the input of a generator130.

The drive train200may include one or more traction motors210,220that receive electrical power from the generator130. In some embodiments, the traction motors are electrical motors that provide torque to a transmission230. When the design loads of the tractor change, the output torque of the transmission may be adjusted by changing a gear ratio of the transmission230while, for example, keeping the traction motors210,220the same.

In some embodiments, the energy module500includes batteries520, power electronics540and an accessory package550. The batteries520may be charged by the generator130connected to a charger, or through a line voltage (not shown) when the truck is parked. In operation, the batteries520may at least partially energize the traction motors210,220, depending on the driving regime of the truck. A cooling subsystem530may control temperature of the batteries520. Elements of the energy module500may be collectively controlled by an energy management controller510that includes, for example, a computer processor or a controller.

The support subsystems modules300,400may include a fuel tank310, an air intake320and an exhaust330, which in operation provide fuel and air to the engine110and route the exhaust gases away from the engine. A drive axle410transfers torque from the transmission230to the drive wheels19. In some embodiments, a shore power420receives a line voltage, transforms that voltage into a DC voltage, and feeds the DC voltage to the battery520(e.g., a high voltage battery for driving the traction motors) and/or a battery440(e.g., a 12 V DC for internal usage within the truck).

Many embodiments of the commercial trucks require compressed air for proper operation. In the illustrated modular truck1000, compressed air is provided by unit430(e.g., a compressor and an air storage tank). The illustrated modular truck1000includes a cab or a cab/sleeper combination340.

FIG. 4is a schematic view of a modular vehicle layout with an embodiment of the present technology. In the illustrated embodiment, the elements of the power plant module (the engine110, the engine gearbox120and the generator130) and the drive train module (the motors210,220and the transmission230) are located centrally within the chassis and generally in line with the drive axle410. A charger522may charge the battery520(also referred to as “rechargeable batteries” or “battery stacks”) either using a line voltage or a voltage provided by the generator130. In the illustrated embodiment, an engine cooling radiator530and an air conditioning condenser535are configured in front of the truck.

In different embodiments, different locations for the elements of the power plant module and the drive train module are also possible. For example, the drive train module may be located peripherally with respect to the chassis or generally parallel with the axles of the front wheels18and the rear wheels19. However, the interface between the generator113and the traction motors210,220remains fixed, such that energy is transferred from the generator110(or the generator110and the batteries520) to the traction motors210,220through electrical cables that are located at the interface between the two modules. Thus, with different designs of the modular trucks, the interface between the power plant module100and the drive train module200remains fixed or generally fixed (i.e., the location of the interface moves a relatively small percentage with respect to the signs of the engine of transmission, 5% or 10% or 15%). As a result, truck design and manufacturing is simplified even when, for example, different engines and transmissions are used in different trucks.

The illustrated modular truck1000includes battery stacks520for storing electrical energy and fuel tank assemblies525for storing fuel. With different modular designs, the space allocated to the battery stacks or the fuel tank assemblies (collectively, “energy storage assemblies”) may be redistributed. For example, the space allocated to the battery stacks520may be increased for trucks that predominantly drive in the city, or the space allocated to the fuel tank assemblies525may be entirely re-allocated to the battery stacks520when the modular truck1000is entirely electrical. In general, the space allocated to these energy storage assemblies and their interfaces toward other modules remain the same or generally the same irrespective of the design of the truck.

In the illustrated embodiment, elements of the energy module500are located peripherally with respect to the chassis. In other embodiments, different locations of these and other modules possible for as long as the locations of these modules and their interfaces with other modules are predefined.

In some embodiments, a compressor432generates compressed air that is stored in one or more air tank assemblies434. The compressor432may be powered from, for example, the truck battery440.

FIGS. 5A and 5Bare respectively top and bottom views of a hybrid truck5000in accordance with an embodiment of the present technology. In these views, the cabin is removed to improve clarity of the views. The illustrated modular hybrid truck includes a compressed natural gas (CNG) engine110(FIG. 5A). The battery stacks520(FIG. 5B) may be at least partially charged by the engine110. In operation, the engine110and the battery stacks520energize a traction motor210through electrical cables212. The traction motor210provides torque to the transmission230, which, in turn, rotates the drive axle410and the drive wheels19.

As explained above, the engine110and the battery stacks520are located within their pre-defined spaces. Other modules and components of the truck (e.g., fuel tank, chassis air supply, etc.) may be laid out within analogously pre-defined spaces and interfaces. Therefore, in many embodiments of the modular truck, selection of different engines, transmission, battery stacks, etc., is simplified. An example of a modular truck that uses a different engine is discussed with respect toFIGS. 6A and 6Bbelow.

FIGS. 6A and 6Bare respectively top and bottom views of a hybrid truck6000in accordance with an embodiment of the present technology. In the illustrated embodiment, the engine110(FIG. 6A) is a fuel cell engine. In operation, the engine110charges battery stacks525(FIG. 6B) and provides energy for the traction motor210. Since the general location of the battery stacks525, the electrical cables212(i.e., an interface to the traction motor210), and other components of the truck remained the same, in at least some embodiments replacing the CNG engine of the modular truck5000with a fuel cell engine of the modular truck6000does not affect or minimally affects the overall design and manufacturability of the truck.

Many embodiments of the technology described above may take the form of computer-executable or controller-executable instructions, including routines executed by a programmable computer or controller. Those skilled in the relevant art will appreciate that the technology can be practiced on computer/controller systems other than those shown and described above. The technology can be embodied in a special-purpose computer, application specific integrated circuit (ASIC), controller or data processor that is specifically programmed, configured or constructed to perform one or more of the computer-executable instructions described above. Of course, any logic or algorithm described herein can be implemented in software or hardware, or a combination of software and hardware.

From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the disclosure. Moreover, while various advantages and features associated with certain embodiments have been described above in the context of those embodiments, other embodiments may also exhibit such advantages and/or features, and not all embodiments need necessarily exhibit such advantages and/or features to fall within the scope of the technology. Accordingly, the disclosure can encompass other embodiments not expressly shown or described herein.