ELECTRIC ATV

An electric ATV having a frame and at least one battery mounted on the frame. 4 hub motors connected to the frame, and a wheel is connected to each of the hub motors. Each of the hub motors includes an independent controller, and the hub motors and associated ones of the controllers each being configured to independently provide both forward and reverse power and torque to the respective wheels to propel the ATV. Each of the hub motors can be mechanically attached to the frame using a quick-release connector and an electrical plug connection, to allow easier service or swapping out in the field. A genset can be provided in place of a battery, and multiple independent controls may also be provided for each motor/controller. An electric ATV with frame mounted motors/independent controllers for each wheel is also provided.

TECHNICAL FIELD

The disclosure is directed to an electric ATV (E-ATV) design that is configured on a standard ATV chassis having a design and configuration which is standard in the Industry. The E-ATV includes a chassis with 4 wheels attached to standard ATV suspension, a passenger seat and standard steering controls with handlebars.

SUMMARY

In one aspect, an E-ATV is provided having a frame, at least one battery mounted on the frame, and 4 hub motors connected to the frame, with a wheel connected to each of the hub motors. Each of the hub motors includes an independent controller, and the hub motors and associated ones of the controllers (hub motor/controller unit) are each configured to independently provide both forward and reverse power and torque to the respective wheels to propel the ATV.

In one embodiment, each of the hub motors is mechanically attached to the frame using a quick-release connector and an electrical plug connection.

Using this arrangement, each wheel forms its own “maintenance system” that can be easily serviced or swapped out in the field in order to allow critical maintenance to be carried out during use in areas outside of normal maintenance facilities.

In another embodiment, the at least one battery defines a battery envelope and the frame includes at least two receiving areas, each configured to accommodate the battery envelope. A hybrid power cell is preferably provided having approximately a same size as the battery envelope and/or that is configured to be received in one of the receiving areas. The hybrid power cell includes a fuel driven generator that is adapted to provide power for recharging the at least one battery. In the current configuration, the hybrid power cell provides power only to recharge the at least one battery and does not directly drive the motors or E-ATV wheels.

In a further embodiment, independent right and left motor switches that are configured to control a forward and reverse direction of both associated motors on a respective right or left side of the electric ATV are provided. Here, the left motor switch controls only the two left motors and the associated independent controllers, and the right switch controls only the two right motors and the associated independent controllers. The right and left motor switches provide movement functions such as the ability to make a “zero point” turn without the use of a computer or torque vectoring system.

In another embodiment, an independent control is provided that is configured to separately supply power to each of the motors and the associated controllers to selectively power one or more wheels. This allows power to be applied to one or more non-slipping wheels only if the ATV is stuck and one or more of the wheels are slipping.

In one preferred arrangement, a multi-function joystick is provided to carry out the different switching functions.

In another aspect, an electric ATV is provided having a frame with at least one battery mounted on the frame, the at least one battery defining a battery envelope and the frame including at least two receiving areas, each configured to accommodate the battery envelope. 4 motors are connected to the frame, and a wheel is drivingly connected to each of the motors in this case via a drive shaft, preferably a CV shaft. Each of the motors includes an independent controller, and the motors and associated ones of the controllers are each configured to independently provide both forward and reverse power and torque to the respective wheels to propel the ATV.

In one embodiment, a gear box is provided in the power train between each motor and the associated drive shaft in order to provide a gear reduction for increased power and torque delivery to the associated wheel.

Various other features as discussed herein can be used in connection with the electric ATV having frame mounted individual drive motor/controllers for each wheel that are drivingly connected to the respective wheels by drive shafts, such as the hybrid power cell that is provided having a same size as the battery envelope and/or can be received in the battery envelope, the independent right and left motor switches, independent controls being configured to separately supply power to each of the motors, as well as the use of a multi-function joystick to carry out the switching.

The features of the above-note embodiments may be used independently or in combinations with two or more of the features combined on a single E-ATV.

DETAILED DESCRIPTION

Certain terminology is used in the following description for convenience only and is not limiting. “Axially” refers to a direction along an axis of an assembly. “Radially” refers to a direction inward and outward from the axis of the assembly. The terms “about” and “approximately” and the like encompass + or −10% of an indicated value unless otherwise noted. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terminology includes the words specifically noted above, derivatives thereof and words of similar import.

E-ATV with 4 Independent Hub Motors and Motor Controllers (Motor/Controller Unit)—One for Each Wheel

Referring toFIGS.1A,1B, and2A-2C, a first embodiment of an E-ATV10is shown that includes a frame12on which 4 hub motors20A-20D and 4 motor controllers30A-30D, which form motor/controller units, which operate independently to provide both forward and reverse power and torque to propel the ATV10, are attached. Each motor/controller20A,30A;20B,30B;20C,30C;20D,30D operates as an independent driving system. Wheels14A-D are attached to the hub motors20A-20D. A handle bar16provides user controls, as explained below. A seat18is also mounted to the frame12.

The hub motors20A-20D are attached to the frame12in a way that they can be “hot swapped” or exchanged quickly without difficulty in the case of failure.FIGS.2A and2Bshow the hub motors20A,20B are mounted to respective upper and lower suspension arms22and24on the frame12. In one preferred embodiment, as shown inFIG.2C, the hub motors20A-20D include respective axle stubs26that extend from the hub motors that fit into a keyway opening27on a hub motor mount28on one side. The hub motor mounts28are pivotally attached to the frame12of the E-ATV10via top and bottom knuckles28A,28B thereon that are pivotally connected to the respective upper and lower suspension arms22and24that are part of the E-ATV suspension. The hub motors20C and20D on the opposite side of the frame12are similarly attached. A quick release connector29, preferably in the form of one or more quick disconnect pins or bolts, hold the axle stub26in the keyway hole27when it is fully inserted. The quick release connector29can be retained for example via a clip, cotter pin or nut, or a combination of one or more of these. The other hub motor assemblies20B-20D are similarly connected to the frame12via the connection of the axle stubs26to the hub motor mounts28. Removal of the quick release connector29allows an individual one of the hub motors20A-20D to be quickly and easily detached from the frame for replacement.

Additionally, as shown inFIG.2C, the electrical connection between the respective hub motor20A-20D and its associated controller30A-30D includes a disconnect plug34on order to allow for easy electrical disconnection of the hub motor20A-20D that is being removed. In the embodiment shown inFIG.2C, the disconnect plug32is shown at the end of the axle stub26and is slidable into a mating connector or plug34that is integrated in the top knuckle28A of the hub motor mount28. However, as would be understood by a person skilled in the art, this connection could be positioned in a different location or could use an external wire and plug.

This arrangement provides significant cost and maintenance benefits for the consumer based on the ability to easily remove and replace a hub motor assembly20A-20D, which preferably all have the same configuration.

Two Separate Batteries Systems for Redundancy and Hot Swap

In another aspect, as shown inFIG.1B, the E-ATV10preferably includes a battery system40that is comprised of two similar size batteries42A,42B that provide power to all four hub motors20A-20D and their associated motor controllers30A-30D. The batteries42A,42B are located in battery compartments or receiving areas44A,44B mounted to the frame12. This allows for maximum power (i.e., from both batteries42A,42B at one time) to any one motor20A-20D at a time when the ATV10needs more or less power to a given motor/controller unit20A,30A;20B,30B;20C,30C;20D,30D. This can be distributed via the controls as described in detail below. These batteries42A,42B also allow for individual “hot swap” scenarios in the case of one battery unit42A,42B failure.

E-ATV Hybrid Power Cell—Hot Swap in Place of One of The Two Batteries

In further embodiment, in addition to the Hot Swap battery system noted above, a hybrid power cell46, shown inFIG.1Cis provided that approximately matches the size of one of the batteries42A,42B and/or can be located in one of the battery compartments44A,44B. This hybrid power cell46preferably includes a fuel supply47and a fuel driven generator (genset)48and can be installed rather than the 2ndbattery42B to provide continuous power (on board charging) to the E-ATV10with a gasoline or another fuel that drives, for example, an internal combustion engine, that is connected to a generator. The hybrid power cell46in this manner can continuously charge the battery42A which simultaneously runs one or more hub motor20A-D or alternatively, can be used to recharge the battery42A when the vehicle is not in motion. In an alternative configuration, the hybrid power cell46can be installed adjacent to a single battery42A in an E-ATV10powered solely by said single battery42A. This genset also functions as an onboard generator that can also provide outlets49to power for applications such as tools, equipment, additional external charging or lighting.

The genset configuration can be provided as a separate item that a consumer can purchase separately. For example, the E-ATV10can be supplied with only one battery42A and a second battery42B or the Genset power system46can be separately purchased as the 2ndmeans of power for the E-ATV10. This genset46effectively becomes the “range extender” for the E-ATV10.

E-ATV Independent Right and Left Handlebar Switch For Independent Control Of Right and Left Motor Systems for Forward, Reverse And Zero Point Turns

In a further embodiment as shown inFIGS.3-7, the E-ATV10includes independent right and left handlebar switches50,52, which may be 3-way rocker switches, to provide a novel and simple method of controlling the forward and reverse direction of both associated motors20A,20B;20C,20D on each respective side of the E-ATV10. The left switch52preferably includes forward, reverse, and neutral positions and controls only the two left hub motor/controller units20C,30C;20D,30D. The right switch52preferably includes forward, reverse, and neutral positions and controls only the right hub motor/controller units20A,30A;20B,30B. This arrangement allows for 4 simple functions without the use of a computer or torque vectoring system to allow for forward, reverse and turning movements.

The functions using the right and left handlebar switches50,52include: a) with both switches50,52(shown inFIG.3) switched to the forward direction, the two left hub motor/controller units20C,30C;20D,30D and the two right hub motor/controller units20A,30A;20B,30B drive in the FORWARD direction to move the E-ATV10forward; b) with both switches50,52(shown inFIG.4) switched to the backward direction, the two left hub motor/controller units20C,30C;20D,30D and the two right hub motor/controller units20A,30A;20B,30B drive in the BACKWARD direction to drive the E-ATV10backward; c) with the left switch52switched to the forward direction, and the right switch50switched in the backward direction (shown inFIG.5) the two left hub motor/controller units20C,30C;20D,30D drive in the FORWARD direction and the two right hub motor/controller units20A,30A;20B,30B drive in the BACKWARD direction to spin the E-ATV10on its axis to the RIGHT in a “zero point” turn; and d) with the left switch switched to the backward direction, and the right switch switched in the forward direction (shown inFIG.6) the two left hub motor/controller units20C,30C;20D,30D drive in the BACKWARD direction and the two right hub motor/controller units20A,30A;20B,30B drive in the FORWARD direction to spin the E-ATV10on its axis to the LEFT in a “zero point” turn.

E-ATV Independent Motor Control

In addition to operating the right and left side wheels independently, it is feasible to operate each wheel independently to transfer differing levels of torque to each wheel. As shown inFIG.7, four switches60A-60D can be provided that are connected to the respective motor/controller20A,30A;20B,30B;20C,30C;20D,30D and independently operate each respective hub motor20A-20D to power one or more wheels in situations where multiple wheels are slipping for example. The use of separate motor controllers30A-D in this configuration of the E-ATV10further eliminates the need for a central computer-module controller that controls all 4 motors20A-D which significantly reduces costs and software complexity of the E-ATV10. In the current configuration of the E ATV10, the need for a central controller to monitor wheel slippage or traction is not needed at normal operating speeds because the hub motors and wheels20A-D,14A-D will “freewheel” (not driving) when traction is more readily available to any of the other wheels. These switches60A-60D can be simple 3-way rockers (or similar) that have forward, reverse or off for each hub motor20A-20D and/or the associated controller30A-30D.

Alternatively, as shown inFIG.8, a toggle or Joystick switch70can be used to directionally power each wheel with additional torque. For example, pushing the Joystick switch70to the upper left would put more power to the front left hub motor/controller20C,30C. Pushing the Joystick switch70to the lower right would put more power to rear right hub motor/controller20B,30B, and so on.

A separate master switch72can be provided that is connected to the controllers30A-30D to control forward or reverse and to engage the toggle capability which could be limited primarily for slow speed operation.

Additionally, the same type of Joystick control can be connected to each hub motor/controller20A,30A;20B,30B;20C,30C;20D,30D instead of the independent switches and can operate the hub motors20A-20D in the same configuration as above with the additional feature of a twisting joystick to turn the ATV on its axis left or right for a zero point turn.

E-ATV with Drive Gear Reduction for Each Wheel

Referring toFIGS.9-11, another embodiment of the E-ATV10′ is shown. The E-ATV10′ includes a frame12′ a frame with at least one battery42A,42B mounted on the frame12′. As discussed above, the at least one battery42A,42B defines a battery envelope and the frame12′ including at least two battery compartments or receiving areas44A,44B mounted to the frame12, with each being configured to accommodate the battery envelope. Here,4motors20A′-20D′ are connected to the frame12′, and a wheel14A-14D is drivingly connected to each of the motors in this case via a drive shaft21′, preferably a CV shaft. Each of the motors20A′-20D′ includes an independent controller30A-30D, as discussed above. The motors20A′-20D′and associated ones of the controllers30A-30D are each configured to independently provide both forward and reverse power and torque to the respective wheels14A-14D to propel the ATV.

Preferably, a separate gear box23A′-23D′ is provided in the power train between each motor20A′-20D′ and the associated drive shaft21′ in order to provide a gear reduction for increased power delivery to the associated wheel14A-14D. The gear reduction can be a fixed ratio, for example 6:1 to 10:1, to provide increased torque to the wheels14A-14D. Alternatively, each gearbox can provide multiple different selectable gear ratios and may be switched or shifted between the different gear ratios via a user input.

The wheels14A-14D in this embodiment of the E-ATV10′ are mounted by upper and lower suspension arms that are pivotally connected to respective wheel hubs and the frame12′ in a known manner.

The E-ATV10′ can include one or more of the genset46as discussed above, the independent right and left handlebar switches50,52as discussed above, the four switches60A-60D for independent motor control as discussed above, and/or the joystick switch70.

In an alternative embodiment, a central control computer module80(indicated inFIG.11) having a processor and associated memory with programming may be used to sense the spin rate of the wheels14A-14D, for example via a sensor located at each wheel14A-14D or via current drawn by the associated motor20A-20D, and when one wheel14A-14D slips and thereby spins significantly faster than the other wheels14A-14D, the central control module80will reduce the speed of the faster rotating wheels to transfer power to the non-slipping wheels. This can also be incorporated in the first embodiment of the E-ATV10.

Many of the features in the embodiments noted above can be used separately or one or more of these features can be combined together in one E-ATV10,10′.

It is noted that some of the electrical connections between the batteries, the controllers30-30D, the motors20A-20D;20A′-20D′, and control switched50,52;60A-60D,70are schematically shown inFIGS.1B and11, and are merely exemplary. Such electrical connections between these elements in order to provide the desired current to the motors and input signals to the controllers30A-30D would be readily understood by the ordinarily skilled artisan based on the present disclosure.

Having thus described the presently preferred embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiments and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope that is indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.