Patent Publication Number: US-2013229092-A1

Title: Electricity generating axle and electricity generating hub for a vehicle

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 12/925,016, filed Aug. 23, 2011, and entitled Generating Axle, which is the non-provisional of U.S. Provisional Patent Application 61/278,844, filed Oct. 14, 2009, the entire contents of which are hereby incorporated by reference in their entirety. 
    
    
     BACKGROUND 
     The increasing cost of fossil fuels as well as environmental concerns have spurred a movement towards energy efficiency as well as energy recovery in vehicles. Hybrid vehicles combining internal combustion engines and electric motors, as well as purely electric vehicles are gaining an increasing share of the market. Many such vehicles also employ energy recovery technologies. One example of such a technology is regenerative braking, whereby the vehicle&#39;s kinetic energy is converted into electrical energy instead of being given off as heat as a result of friction braking. 
     SUMMARY 
     According to at least one exemplary embodiment, a generating axle for a vehicle is disclosed. The generating axle can include a hollow, tubular housing, a shaft rotatably disposed within the housing, at least one armature carried by the shaft, and at least one permanent magnet carried by the housing, wherein the at least one armature and the at least one permanent magnet are disposed such that a current is induced in the armature when the shaft is rotated with respect to the housing. 
     According to another exemplary embodiment, a generating wheel hub for a vehicle is disclosed. The generating wheel hub can include a hollow, tubular housing, a shaft rotatably disposed within the housing, at least one armature carried by the shaft, and at least one permanent magnet carried by the housing, wherein the at least one armature and the at least one permanent magnet are disposed such that a current is induced in the armature when the housing is rotated with respect to the shaft. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments. The following detailed description should be considered in conjunction with the accompanying figures in which: 
         FIG. 1  is an exemplary diagram of a vehicle having generating axles. 
         FIGS. 2   a - 2   d  are diagrams of exemplary layouts of vehicles having generating axles. 
         FIG. 3  is a longitudinal section view of an exemplary embodiment of a generating axle. 
         FIGS. 4   a - 4   b  are cross section views of exemplary embodiments of generating axles. 
         FIG. 5  is a longitudinal section view of an exemplary embodiment of a generating wheel hub. 
     
    
    
     DETAILED DESCRIPTION 
     Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows. 
     As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiment are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation. 
     Generally referring to  FIGS. 1-4   b  and according to at least one exemplary embodiment, a generating axle  100  for a vehicle  10  is disclosed. The generating axle  100  can include a tubular outer housing  102  and a shaft  104  rotatably disposed within the housing. The shaft  104  can carry an armature  106 , while the housing  102  can carry a plurality of permanent magnets  108 . 
     In some exemplary embodiments, a plurality of generating axles  100  may be provided on a vehicle  10 . In some exemplary embodiments, the generating axles  100  may be provided in lieu of conventional axle half-shafts that are coupled to the wheels  12  of the vehicle, and the shafts  104  of the generating axles  100  may be driven by the vehicle&#39;s drivetrain. For example, in vehicles having FF, RR, or RMR layouts, the generating axles  100  may be disposed between the transmission  14  and the drive wheels  12  of the vehicle. In vehicles having FR or similar layouts, the generating axles  100  may be disposed between the rear differential  16  and rear wheels  12  of the vehicle. In four wheel drive or all wheel drive vehicles, the generating axles  100  may be disposed between both the transmission  14  and the front wheels  12  of the vehicle, as well as between the rear differential  16  of the vehicle. In other exemplary embodiments, the generating axles  100  may be provided as non-driving axles of a vehicle, for example in place of any type of dead axle of the vehicle or on a trailer of the vehicle. However, the above examples should not be construed as limiting, and any arrangement that allows the generating axles  100  to function as described herein may be contemplated and provided as desired. 
     The generating axle  100  may be joined to the other components of the vehicle in any known manner that allows the axles to function as described herein. For example the shafts  104  of the generating axles  100  may be joined to the other components of the vehicle, such as wheels, transmission output shafts, differentials, and so forth by way of CV joints, universal joints, gearing arrangements, or the like. The housing  102  of the generating axle  100  may be joined to any suitable component of the automobile frame, suspension, and so forth, so as to allow housing  102  to remain stationary with respect to the rotation of shaft  104  therein. For example, in a live axle setup, housing  102  of the generating axle  100  may be coupled to the differential housing, or may be provided integrally with the differential housing. In other suspension setups, the housing  102  may be provided in any way that can allow the housing to enclose shaft  104  and for shaft  104  to rotate freely within the housing  102  during operation of the vehicle. It is envisioned that embodiments of the generating axle  100  may be adapted for any desired vehicle suspension arrangement. 
     An armature  106 , formed from a conductive material such as copper, may be carried by the shaft  104  of the generating axle. The armature  106  can include a plurality of windings of the conductive material, which may be provided in any desired number and configuration. The armature  106  can be disposed over a portion of the length of shaft  104 , or for substantially the entirety of the length of shaft  104 . The windings of armature  106  can be disposed in any arrangement or orientation that induces a current in armature  106  when shaft  104  is rotated with respect to housing  102 . 
     In some exemplary embodiments, armature  106  may be coupled to and may cover the surface of shaft  104 . A clearance between armature  106  and the inner surface of housing  102  may be provided so as to allow shaft  104  and armature  106  to rotate freely within housing  102 . In other exemplary embodiments, the windings of armature  106  may be disposed within grooves or channels  110  defined in the outer surface of shaft  104  such that armature  106  does not protrude beyond the outer surface of shaft  104 . In such embodiments, the clearance between armature  104  and the inner surface of housing  102  may be reduced. 
     A plurality of permanent magnets  108  may be carried by housing  102 . The magnets  108  may be disposed on or proximate the inner surface of housing  102  in at least one location corresponding to the location of armature  106 . Both the orientation of magnets  108  as well as the distance of magnets  108  from armature  106  may be selected so as to induce a current in armature  106  when shaft  106  is rotated with respect to housing  104 . 
     Embodiments of generating axle  100  may be adapted as desired to provide direct current or alternating current to the electrical system of the vehicle. The embodiments of generating axle  100  may further be adapted to provide electrical power at any desired voltage. The transmission of generated electrical power from the rotating armature  106  to any static part of the vehicle may be provided in any manner known in the art, including brushes, slip rings, commutators, or any other known structure that enables the generating axle  100  to function as described herein. 
     The armature  106  of each generating axle  100  may be electrically coupled to the electrical system of the vehicle. In some exemplary embodiments, the armature  106  of each generating axle  100  may be electrically coupled to at least one battery  112 . The electricity generated by each generating axle  100  may be stored in the battery  112 . If necessary, a rectifier may be provided between generating axle  100  and battery  112  or any other suitable part of the electrical system of the vehicle. 
     In some exemplary embodiments, the operation of generating axle  100  may be controlled by a control unit  114  of the vehicle. Consequently, the operation of axle  100  may be controlled so as to generate electrical power only in desired situations or in response to desired actions. For example, generating axle  100  may be operable when a reduction of vehicle speed is desired, and can thus perform a regenerative braking function. As another illustrative example, if a vehicle has a plurality of generating axles  100 , the operation of each generating axle  100  may be controlled separately based on any desired criteria or conditions. 
       FIG. 3  shows an exemplary embodiment of a generating wheel hub  200 . The exemplary embodiment of generating wheel hub  200  may be used on two-wheeled vehicles such as bicycles, mopeds, motorcycles, and the like, or any other vehicle where wheel hubs are used in place of axles. The generating wheel hub  200  may be used in lieu of standard wheel hubs of the vehicle. To that end, the generating wheel hub  200  may include a shaft  204  which may be coupled to the suspension, or any other suitable member of the vehicle, and may be supported within housing  202  by bearings  205 . Housing  202 , in turn, may be coupled to the wheel of the vehicle. When the vehicle is in operation, the shaft  204  may remain stationary while housing  202  may rotate when the wheel of the vehicle is in motion. 
     Similarly to the generating axle  100 , an armature  206  may be carried by the shaft  204  of the generating hub  200 . The armature  206  can include a plurality of windings of the conductive material, which may be provided in any desired number and configuration. The armature  206  can be disposed over a portion of the length of shaft  204 , or for substantially the entirety of the length of shaft  204 . The windings of armature  206  can be disposed in any arrangement or orientation that induces a current in armature  206  when housing  202  is rotated with respect to shaft  204 . Furthermore, similar to the generating axle  100 , the armature  206  may be disposed on the surface of shaft  204 , or within a groove or channel defined in the outer surface of shaft  204  such that armature  206  does not protrude beyond the outer surface of shaft  204 . 
     A plurality of permanent magnets  208  may be carried by housing  202 . The magnets  208  may be disposed on or proximate the inner surface of housing  202  in at least one location corresponding to the location of armature  206 . Both the orientation of magnets  208  as well as the distance of magnets  208  from armature  206  may be selected so as to induce a current in armature  206  when housing  204  is rotated with respect to shaft  202 . 
     The embodiments of generating hub  200  may be adapted as desired to provide direct current or alternating current to the electrical system of the vehicle and to provide electrical power in any desired voltage. The armature  206  of each generating hub  200  may be electrically coupled to the electrical system of the vehicle in any manner known in the art. In some exemplary embodiments, the armature  206  of each generating hub  200  may be electrically coupled to at least one battery  212 . Furthermore, similar to generating axle  100 , the operation of generating hub  200  may be controlled, if desired, by a control unit of the vehicle. Alternatively, on some vehicles such as bicycles, the operation of generating hub  200  may be controlled manually. Consequently, the operation of hub  200  may be controlled so as to generate electrical power only in desired situations or in response to desired actions. For example, generating hub  200  may be operable when a reduction of vehicle speed is desired, and can thus perform a regenerative braking function. 
     In some exemplary embodiments, the generating axle  100  and generating wheel hub  200  may be provided as a replacement part for vehicles not having regenerative braking or other energy recovery abilities. Embodiments of the generating axle and generating hub disclosed herein may be adapted for various such vehicle models and may be used to replace conventional axles or wheel hubs on such vehicles. The generating axles or wheel hubs may then be electrically coupled to the electrical system of the vehicle, thereby providing additional electrical power, as well as regenerative braking capabilities to the vehicle. An exemplary vehicle on which the generating axles may be used may be trailers or other large cargo vehicles, for example trailers having large power consumption requirements. Use of the generating axle on vehicles such as trailers can provide additional power to the vehicle and can also reduce the wear on the braking components of the vehicle. Exemplary vehicles on which the generating wheel hubs may be used include motorcycles or bicycles, where the additional generated electricity may be used to power accessories such as additional lights, heated elements, and so forth. 
     The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art. 
     Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.