Electrically driven PTO

Abstract

A robotic vehicle having a battery powered power take off (PTO) shaft. A single battery powers a PTO motor directly connected to a torque converter having a PTO shaft output and two independent track motors.

Description

Technical Field

[0001] The present disclosure relates to autonomous vehicles and, more particularly, to electric drive power take-offs (PTOs). Background Art

[0002] There are many situations where autonomous vehicles are superior to human-operated vehicles. Such autonomous vehicles are particularly advantageous for performing hazardous missions or operating in hazardous conditions, similar to what a first responder or explosive ordnance disposal team might experience. They are also advantageous in situations where large fleets of vehicles are required, such as in agriculture, where the size of farms has increased, but the limited time windows for agricultural operations remain the same. Regardless of the situation, personnel need autonomous vehicles that are easily accessible and robust enough to operate in all conditions.

[0003] Some large conventional powered vehicles (such as trucks, tractors, and even ships) use a power take-off (PTO) system to provide power to an attached or separate machine. Typically, a PTO device draws power from the vehicle's internal combustion engine via a PTO shaft. Common applications for PTO systems include mowers, threshers, and harvesters running on agricultural vehicles. The use of PTOs on vehicles used in other industries is generally known to those skilled in the art.

[0004] Therefore, there is a need in the art for methods, systems and / or devices that can assist people in performing various operations. Such methods, systems and / or devices can be used to reduce the time to complete an operation, improve the conditions under which an operation can be completed, reduce the amount of manpower required, or otherwise reduce the number of problems associated with agriculture and other industries. Summary of the invention

[0005] According to one aspect of the present invention, a robotic vehicle is disclosed, comprising: a battery unit; a motor controller electrically connected to the battery unit; a motor connected to the motor controller; a torque converter connected to the motor; and a power take-off (PTO) shaft extending from a gearbox. The output of the motor may be coplanarly positioned above the PTO shaft.

[0006] In one embodiment, each torque converter also includes a motor input gear coupled to the output of the motor, an input idler gear coupled to the motor input gear, and a PTO output gear coupled to the input idler gear and coaxially coupled to the PTO shaft. The torque converter may include an output idler gear coupled to the PTO output gear and an idler shaft axially coupled to the output idler gear.

[0007] Each torque converter may include a front plate, a middle plate, and a rear plate to position the motor input gear above the input idler gear, position the PTO output gear adjacent to the input idler gear, and position the output idler gear above the PTO output gear. A front cover and a rear cover enclose the front plate, the middle plate, and the rear plate. The torque converter may include a motor input shaft coupled to the output of the motor, wherein the motor input shaft is coplanarly positioned above the PTO shaft, wherein the motor extends away from the torque converter toward the rear of the chassis in the direction of the PTO shaft.

[0008] In one embodiment, a coolant system is operably connected to the motor controller and the motor for dissipating heat from the motor controller and the motor. The coolant system includes a cooler and a pump for circulating the coolant around the controller and the motor and returning to the cooler. The cooler may be positioned above the motor. The motor controller may be positioned in the operating unit behind the battery unit and above the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] By reading and attaching Figure 1 These and other features and advantages of the present invention will be better understood from the following detailed description, in which: Figure 1 is a perspective view of a robotic vehicle according to the present disclosure.

[0010] Figure 2 yes Figure 1 Exploded view of a robotic vehicle with the hitch, PTO assembly, and central electronics and cooling assembly separated from the operating unit.

[0011] Figure 3 is a perspective view of the exterior of the PTO and center electronics and cooling assembly.

[0012] Figure 4 is an exploded view of the center electronics and cooling assembly with the side covers, rear cooling compartment, coolant pump, motor controller, reservoir, and onboard charger separated from the operating unit.

[0013] Figure 5 A perspective view from the left side of the center and PTO cooling system.

[0014] Figure 6 A perspective view from the right side of the center and PTO cooling system.

[0015] Figure 7 This is an exploded view of the gearbox.

[0016] Figure 8 is an electrical schematic of the center and PTO cooling system.

[0017] Fig. 9 It is the cooling schematic diagram of the central and PTO cooling system. DETAILED DESCRIPTION

[0018] Figure 1 is a perspective view of a robotic vehicle 100 according to the present disclosure. The robotic vehicle 100 is electrically powered and remotely operable to perform manpower-intensive or high-risk functions without exposing the operator to fatigue or danger. The robotic vehicle 100 is robust and rugged to operate in challenging environments. Its low, forward center of gravity allows for towing or hauling of equipment many times its weight. With easily replaceable battery cells 200, the robotic vehicle 100 can operate for many hours and then quickly replace the battery pack for continued operation.

[0019] The robotic vehicle 100 includes a central unit 101 having a chassis 102 having a front end 102a and a rear end 102b supported on right and left track assemblies 104, 106. Each right and left track assembly 104, 106 has its own motor drive that is removably connected to an operating unit 112 where the circuitry and software required to operate the robotic vehicle 100 is located. A front cover 114 protrudes outwardly from the operating unit 112 of the central unit 101 and each motor drive assembly 108, where auxiliary equipment such as a camera 111 and a light 113 may be located.

[0020] The battery unit 200 is below the front hood 114, on the chassis 102, and between the right track assembly 104 and the left track assembly 106. The battery unit 200 may account for approximately 25-30% of the total weight of the robotic vehicle 100, which weighs more than 1500 pounds. By positioning the battery unit 200 on the chassis 102 below the front hood 114, the center of gravity of the robotic vehicle 100 is lowered and moved forward to improve traction and towing capabilities. The battery unit 200 and chassis 102 are more fully described in U.S. Patent No. 11,407,298, filed on November 15, 2021, the contents of which are incorporated herein by reference.

[0021] The robotic vehicle 100 includes a right track assembly 104 and a left track assembly 106, each of which can be removably attached from a chassis 102 of a central unit 101 of the robotic vehicle 100 so that the robotic vehicle 100 can be easily configured for a variety of applications. The track assembly 104 is more fully described in U.S. Patent No. 11,364,959, filed on December 27, 2021, the contents of which are incorporated herein by reference.

[0022] Figure 2 A side view of a robotic vehicle 100 having an electric drive PTO system 300 according to the present disclosure is shown, and for clarity, Figure 3 The operating unit 112 is shown separated from the other systems of the central unit 101. The electric drive PTO system 300 is on the rear side of the operating unit 112, separate from the corresponding right track assembly 104 and left track assembly 106. The electric drive PTO system 300 provides auxiliary power to equipment (such as a hitch 400) through one or more PTO shafts 302.

[0023] Steering Figure 4 , showing the electric drive PTO system 300 in more detail. The battery unit 200 (from Figure 1 ) is electrically connected to the onboard charger 301, which is electrically connected to the motor controller 306. For the motor 308 ( Figure 5 ), the motor controller 306 can be implemented as an inverter, which is used to convert the DC voltage from the battery unit 200 into variable frequency AC power to the motor 308. For the motor 308 implemented as a DC motor, the motor controller 306 can control the rotation speed and torque of the motor 308 by adjusting the current and voltage applied to the motor 308. In this case, a single battery unit 200 can provide power for the right track assembly 104 and the left track assembly 106 and the PTO system 300. The battery unit 200 is also directly connected to the PTO system 300, which has a motor controller 306 directly connected to the motor 308, which means that the PTO motor 308 operates independently of the traction motors in the right track assembly 104 and the left track assembly 106.

[0024] In both cases, the onboard charger 301, motor 308, and motor controller 306 may be cooled to maintain optimal operating conditions. Figure 5 to Figure 6 and Fig. 9 (which shows a high-level schematic diagram of the coolant system 310), the coolant system 310 includes a cooler 312 with a built-in fan in fluid communication with a coolant reservoir 314 and a pump 316. Through a series of hoses 325, the pump 316 circulates coolant from the coolant reservoir 314 around the motor 308, the motor controller 306, and the onboard charger 301 to the cooler 312, where excess heat can be dissipated. It will be noted that the cooler 312 with a built-in fan is uniquely positioned near the rear of the robotic vehicle 100.

[0025] Steering Figure 5 and Figure 6 , a PTO torque converter 320 is provided to position the motor 308 relative to the PTO shaft 302. In the illustrated embodiment, the output of the motor 308 is coplanar with the PTO shaft 302, but faces axially in the opposite direction. An internal gear in the PTO torque converter 320 connects the output of the motor 308 to the PTO shaft 302.

[0026] Torque converter 320 Figure 5 to Figure 6 as well as Figure 7 This is best exemplified in Figure 5 to Figure 6 A front perspective view of the torque converter 320 is shown. Figure 7 An exploded view of the torque converter 320 is shown, defined by the dimension between the front cover 318 and the rear cover 321. Figure 7 Initially, the output shaft of the motor 308 is coupled to the torque converter 320 via the motor input shaft 309. The motor input shaft 309 is axially coupled to the motor input gear 303, which meshes with the input idler gear 304. The idler gear 304 is axially coupled to the idler shaft 307, which is also axially coupled to the output idler gear 305. The output idler gear 305 meshes with the PTO output gear 313, which is axially coupled to the PTO shaft 302.

[0027] The aforementioned gears are located in the front plate 315, the middle plate 317 and the rear plate 323, which are all sealed together between the front cover 318 and the rear cover 321.

[0028] All of the above components are mechanically connected together in an innovative arrangement where the motor 308 is vertically elevated above the PTO shaft 302 and the axis of rotation of the output of the motor 308 is above the axis of rotation of the PTO shaft 302 to keep it elevated high enough from the ground to avoid dust and debris. The mechanical equipment connecting these components together is isolated within a narrow five-inch thick torque converter 320.

[0029] Figure 8 yes Figure 5 to Figure 6 1. A high level electrical schematic diagram of an electric drive PTO of the robotic vehicle 100. The central unit 101 of the robotic vehicle 100 includes a battery unit 200 electrically connected to an operating unit 112, which contains the necessary software and hardware to drive and control the robotic vehicle 100. The battery unit 200 is also connected to a motor controller 306. Thus, power from the battery unit 200 and bidirectional control and response signals from the operating unit 112 are directly supplied to the motor controller 306. The battery unit 200 also supplies power to the cooler 312 and the pump 316 through a low voltage DC relay 319.

[0030] The above-described electric drive PTO system 300 is included in the robotic vehicle 100 and includes a coolant system 310 that is operably connected to the motor controller 306 and the motor 308 for dissipating heat from the motor controller 306 and the motor 308. The coolant system 310 may include a cooler 312 and a pump 316 for circulating coolant around the motor controller 306 and the motor 308 to the cooler 312. In one embodiment, the motor controller 306 is positioned forward of the cooler 312 relative to the front of the robotic vehicle 100 and positioned above the PTO torque converter 320 (including the motor 308). In this regard, the coolant system 310 and the motor controller 306 are positioned such that the operating unit 112 is separated from the right track assembly 104 and the left track assembly 106. The PTO torque converter positions the output of the motor 308 to be coplanar with the PTO shaft 302 in an axially opposite direction.

[0031] Those skilled in the art will appreciate that the above described embodiments are exemplary. Other changes and modifications to the robotic vehicle 100 are contemplated herein. In an alternative embodiment, a single motor controller 192 may be located in the central unit 101 and configured to provide power to the motors 154 for the left track assembly 106 and the right track assembly 104. Similarly, a single coolant system 190 may be located in the central unit 101 with an additional quick release connection for the hose 199. Such a modification provides the modular benefits of the illustrated embodiment, but is currently considered disadvantageous due to the lack of availability or cost of a single motor controller 192 to drive multiple motors 154.

[0032] Unless given a different meaning, the terms used herein are considered to have their ordinary meaning to those skilled in the art. Basically, as used herein, the terms are defined to have standard dictionary definitions, which are most but not all of the definitions specified.

[0033] Although the principles of the present invention have been described herein, it will be appreciated by those skilled in the art that this description is intended only as an example and not as a limitation on the scope of the present invention. In addition to the exemplary embodiments shown and described herein, other embodiments may be considered within the scope of the present invention. Modifications and substitutions made by those of ordinary skill in the art are considered to be within the scope of the present invention, and the scope of the present invention is limited only by the appended claims.

Claims

1. A robot vehicle, comprising: Battery cells; a motor controller electrically connected to the battery unit; a motor connected to the motor controller; a torque converter connected to the electric motor; as well as A power take-off (PTO) shaft extends from the gearbox.

2. The robotic vehicle of claim 1, further comprising, wherein: The output of the motor is positioned coplanarly above the PTO shaft.

3. The robotic vehicle of claim 2, wherein: Each torque converter also includes a motor input gear coupled to an output of the motor, an input idler gear coupled to the motor input gear, and a PTO output gear coupled to the input idler gear and coaxially coupled to the PTO shaft.

4. The robotic vehicle of claim 3, wherein: The torque converter also includes an output idler gear coupled to the PTO output gear and an idler shaft axially coupled to the output idler gear.

5. The robotic vehicle of claim 4, wherein: Each torque converter also includes a front plate, a mid plate, and a rear plate to position the motor input gear above the input idler gear, position the PTO output gear adjacent to the input idler gear, and position the output idler gear above the PTO output gear.

6. The robotic vehicle of claim 5, wherein: The torque converter further includes a front cover and a rear cover to enclose the front plate, the middle plate and the rear plate.

7. The robotic vehicle of claim 1, further comprising a coolant system operably connected to the motor controller and the motor for removing heat from the motor controller and the motor.

8. The robotic vehicle of claim 7, wherein: The coolant system includes a chiller and a pump for circulating coolant around the controller and the motor and back to the chiller.

9. The robotic vehicle of claim 8, wherein: The cooler is positioned above the motor.

10. A robot vehicle, comprising: a chassis, which includes a right side and a left side; an operating unit positioned at the rear of the chassis; a battery unit positioned in front of the chassis; A PTO motor controller electrically connected to the battery unit; a PTO motor connected to the PTO motor controller; a torque converter connected to the PTO motor; a PTO shaft extending from the gear case; a coolant system operably connected to the PTO motor controller and the PTO motor for dissipating heat from the PTO motor controller and the PTO motor; a right track assembly that is detachable from the right side of the chassis; as well as A left track assembly is detachable from the left side of the chassis, wherein each of the right track assembly and the left track assembly includes a track motor operably connected to a track.

11. The robotic vehicle of claim 10, wherein: The coolant system includes a chiller and a pump for circulating coolant around the PTO motor controller and the PTO motor and back to the chiller.

12. The robotic vehicle of claim 11, wherein: The PTO motor is positioned above the right track assembly and the left track assembly to position the PTO motor a sufficient distance above the ground.

13. The robotic vehicle of claim 12, further comprising, wherein: The output of the PTO motor is positioned coplanarly above the PTO shaft.

14. The robotic vehicle of claim 13, wherein: Each torque converter also includes a motor input gear coupled to the output of the PTO motor, an input idler gear coupled to the motor input gear, and a PTO output gear coupled to the input idler gear and coaxially coupled to the PTO shaft.

15. The robotic vehicle of claim 14, wherein: The torque converter also includes an output idler gear coupled to the PTO output gear and an idler shaft axially coupled to the output idler gear.

16. The robotic vehicle of claim 15, wherein: Each torque converter also includes a front plate, a mid plate, and a rear plate to position the motor input gear above the input idler gear, position the PTO output gear adjacent to the input idler gear, and position the output idler gear above the PTO output gear.

17. The robotic vehicle of claim 16, wherein: The torque converter further includes a front cover and a rear cover to enclose the front plate, the middle plate and the rear plate.

18. The robotic vehicle of claim 10, wherein: The PTO motor controller is positioned behind the battery unit in the operating unit and is positioned above the PTO motor.

19. The robotic vehicle of claim 14, wherein: The torque converter also includes a motor input shaft coupled to an output of the PTO motor, wherein the motor input shaft is positioned coplanarly above the PTO shaft, wherein the PTO motor extends away from the torque converter toward the rear of the chassis in the direction of the PTO shaft.

20. The robotic vehicle of claim 14, wherein: A single battery unit powers the PTO motor and the track motor of each right and left track assembly, and wherein the PTO motor operates independently of the track motor of each right and left track assembly.

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