Electrically driven PTO

Abstract

A robotic vehicle equipped with a battery-driven power take-off (PTO) shaft. One battery powers a PTO motor directly coupled 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 an electric drive power take-off (PTO).

Background Art

[0002] Autonomous vehicles are often preferred over human-operated vehicles. Such autonomous vehicles are particularly advantageous when performing dangerous tasks such as those experienced by first response teams and bomb disposal units, or operating in dangerous situations. They are also advantageous in situations where a large fleet is required, such as in agriculture where the size of farms has increased but the limited time window for farming operations remains the same. In any situation, personnel require autonomous vehicles that are readily available and robust enough to operate in all situations.

[0003] Among conventional power-driven large vehicles such as trucks, tractors, and even ships, there are those that use a power take-off (PTO) system to supply power to attached or separate machinery. Typically, a PTO device draws power from an internal combustion engine of a vehicle via a PTO shaft. Common uses of PTO systems include powering mowers, threshers, and harvesters in agricultural vehicles. The uses of PTOs in vehicles used in other industries are generally known to those skilled in the art.

[0004] Accordingly, there is a need in the art for methods, systems, and / or devices that can assist humans in completing various tasks. Such methods, systems, and / or devices can be used to shorten the time to complete a task, improve the conditions under which a task can be completed, reduce the amount of human labor 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 that includes 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 can be arranged coplanar above the PTO shaft.

[0006] In one embodiment, each torque converter further 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 can 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 mid plate, and a back plate to arrange the motor input gear above the input idler gear, the PTO output gear adjacent to the input idler gear, and the output idler gear above the PTO output gear. A front cover and a rear cover surround the front plate, the mid plate, and the back plate. The torque converter can include a motor input shaft coupled to the output of the motor, and the motor input shaft is arranged coplanar above the PTO shaft in a state where the motor extends away from the torque converter to 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 to dissipate heat from the motor controller and the motor. The coolant system includes a cooler and a pump for circulating coolant around the controller and the motor and back to the cooler. The cooler can be disposed above the motor. The motor controller can be disposed within the operation unit behind the battery unit and can be disposed above the motor.

Brief Description of the Drawings

[0009] These and other features and advantages of the present invention will be better understood by reading the following detailed description together with the drawings.

[0010]

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Best Mode for Carrying Out the Invention

[0011] FIG. 1 is a perspective view of a robotic vehicle 100 according to the present disclosure. The robotic vehicle 100 is electrically driven and remotely operable to perform manual-intensive or high-risk functions without exposing an operator to fatigue or danger. The robotic vehicle 100 is rugged and durable to operate in difficult environments. Due to its low front center of gravity, it can tow or carry equipment that is several times its weight. With an easily replaceable battery unit 200, the robotic vehicle 100 can operate for hours and then immediately replace the battery pack to continue operation.

[0012] The robotic vehicle 100 includes a central unit 101 having a chassis 102 with a front end 102a and a rear end 102b supported by a right track assembly 104 and a left track assembly 106. Each of the right track assembly 104 and the left track assembly 106 has its own motor drive unit that can be removably connected to an operation unit 112, and the operation unit 112 is arranged with the circuits and software necessary to operate the robotic vehicle 100. A front hood 114 protrudes outward from the central unit 101 and the operation unit 112 of each motor drive assembly 108, and auxiliary devices such as a camera 111 and a light 113 can be arranged here.

[0013] Under the front hood 114, on the chassis 102, and between the right track assembly 104 and the left track assembly 106, there is a battery unit 200. The battery unit 200 weighs over 1,500 pounds and can approach 25 - 30% of the total weight of the robotic vehicle 100. By placing the battery unit 200 under the front hood 114 on the chassis 102, the center of gravity of the robotic vehicle 100 is lowered and moved forward, improving traction and towing capacity. The battery unit 200 and the chassis 102 are described in more detail in U.S. Patent No. 11,407,298, filed on November 15, 2021, the content of which is incorporated herein by reference.

[0014] The robotic vehicle 100 includes a right track assembly 104 and a left track assembly 106 that are each removably attachable from the chassis 102 of the central unit 101 of the robotic vehicle 100 to enable the robotic vehicle 100 to be easily configured for various applications. The track assembly 104 is described in more detail in U.S. Patent No. 11,364,959, filed on December 27, 2021, the content of which is incorporated herein by reference.

[0015] FIG. 2 shows a side view of the robotic vehicle 100 having an electric drive PTO system 300 according to the present disclosure, and FIG. 3 shows an operating unit 112 separated from other systems of the central unit 101 for clarity. The electric drive PTO system 300 is on the back side of the operating unit 112 separated from each of the right track assembly 104 and the left track assembly 106. The electric drive PTO system 300 provides auxiliary power to a device (such as a hitch 400) by means of one or more PTO shafts 302.

[0016] Turning to FIG. 4, the electric drive PTO system 300 is shown in more detail. The battery unit 200 (from FIG. 1) is electrically connected to an in-vehicle charger 301 that is electrically connected to a motor controller 306. In the case of the motor 308 implemented as an AC motor (shown in FIG. 5), the motor controller 306 can be implemented as an inverter for converting the DC voltage from the battery unit 200 into variable frequency AC power to the motor 308. In the case of the motor 308 implemented as a DC motor, the motor controller 306 can control the rotational speed and torque of the motor 308 by adjusting the current and voltage applied to the motor 308. In this embodiment, a single battery unit 200 can supply power to both the right and left track assemblies 104, 106 and the PTO system 300. The battery unit 200 is also directly connected to the PTO system 300 having the motor controller 306 directly connected to the motor 308, which means that the PTO motor 308 operates independently of the traction motors of the right and left track assemblies 104, 106.

[0017] In either case, the in-vehicle charger 301, the motor 308, and the motor controller 306 may be cooled to maintain an optimal operating state. Referring to FIGS. 5 - 6 and FIG. 9, which show a high-level schematic of the coolant system 310, the coolant system 310 includes a coolant reservoir 314 and a fan-integrated cooler 312 that is in fluid communication with a pump 316. The pump 316 circulates coolant from the coolant reservoir 314 around the motor 308, the motor controller 306, and the in-vehicle charger 301 through a series of hoses 325 and sends it to the cooler 312 where excess heat can be dissipated. It can be seen that the fan-integrated cooler 312 is uniquely located near the rear of the robotic vehicle 100.

[0018] Looking at FIGS. 5 and 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 in the same plane as the PTO shaft 302 but is axially oriented in the opposite direction. The internal gears of the PTO torque converter 320 connect the output of the motor 308 to the PTO shaft 302.

[0019] The torque converter 320 is best shown in FIGS. 5 - 6, which show a front perspective view of the torque converter 320, and in FIG. 7, which shows an exploded view of the torque converter 320 defined by the dimensions between the front cover 318 and the rear cover 321. Referring to FIG. 7, 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 engages 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 engages the PTO output gear 313, which is axially coupled to the PTO shaft 302.

[0020] The aforementioned gears are disposed on the front plate 315, the mid - plate 317, and the back plate 323, all of which are sealed between the front cover 318 and the rear cover 321.

[0021] In an innovative arrangement where the motor 308 rises vertically 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, all of the aforementioned components are mechanically connected and are kept sufficiently high above the ground so as not to attract dust and debris. All of the mechanical devices connecting these components are narrow in width and are isolated inside the 5 - inch - thick torque converter 320.

[0022] Figure 8 is a high-level electrical circuit diagram of the electric drive PTO of FIGS. 5-6. The central unit 101 of the robotic vehicle 100 includes a battery unit 200 that is electrically connected to an operation unit 112 that includes the software and hardware necessary to drive and control the robotic vehicle 100. The battery unit 200 is also connected to the motor controller 306. Thus, the power from the battery unit 200, and the bidirectional control and response signals from the operation unit 112 are supplied directly to the motor controller 306. The battery unit 200 also supplies power to the cooler 312 and the pump 316 via a low voltage DC relay 319.

[0023] The electric drive PTO system 300 described above is included in the robotic vehicle 100 and includes a coolant system 310 operably connected to the motor controller 306 and the motor 308 to dissipate the 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 and sending it to the cooler 312. In one embodiment, the motor controller 306 is disposed in front of the cooler 312 with respect to the front of the robotic vehicle 100 and above the PTO torque converter 320 that includes the motor 308. In this regard, the cooling device 310 and the motor controller 306 are disposed separately from the operation unit 112 from the right track assembly 104 and the left track assembly 106. The PTO torque converter places the output of the motor 308 in the same plane as the PTO shaft 302 in the axially opposite direction.

[0024] One skilled in the art will understand that the illustrated embodiments described above are exemplary. Other changes and modifications to the robotic vehicle 100 are contemplated herein. In an alternative embodiment, a single motor controller 192 can be disposed in the central unit 101 and configured to supply power to the motors 154 for the left track assembly 106 and the right track assembly 104. Similarly, a single coolant system 190 can be disposed in the central unit 101 having additional quick release connections for the hoses 199. Such changes provide the modular advantages of the illustrated embodiments, but are presently considered disadvantageous because a single motor controller 192 for driving multiple motors 154 may not be available or may be costly.

[0025] The terms used herein are presumed to have the ordinary meaning to one of ordinary skill in the art, unless a different meaning is provided. As used herein, "substantially" is defined to have the meaning of "mostly what is specified, but not all" as in the standard dictionary definition.

[0026] Although the principles of the present invention have been described herein, it should be understood by those skilled in the art that this description is by way of example only and is not intended to limit the scope of the invention. Other embodiments are also contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Changes and substitutions by those skilled in the art are considered to be within the scope of the present invention, which is not limited except as set forth in the following claims.

Claims

1. A robotic vehicle, 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; a power take-off (PTO) shaft extending from a gearbox; the robotic vehicle.

2. The robotic vehicle according to claim 1, further comprising an output of a motor disposed on the same plane above the PTO shaft. The robotic vehicle according to claim 1.

3. Each torque converter further comprises: a motor input gear coupled to an output of the motor; an input idler gear coupled to the motor input gear; a PTO output gear coupled to the input idler gear and coaxially coupled to the PTO shaft. The robotic vehicle according to claim 2.

4. The torque converter further comprises: an output idler gear coupled to the PTO output gear; an idler shaft axially coupled to the output idler gear. The robotic vehicle according to claim 3.

5. Each torque converter further comprises a front plate, a mid plate, and a back plate for disposing the motor input gear above the input idler gear, disposing the PTO output gear adjacent to the input idler gear, and disposing the output idler gear above the PTO output gear. The robotic vehicle according to claim 4.

6. The torque converter further comprises a front cover and a rear cover surrounding the front plate, the mid plate, and the back plate. The robotic vehicle according to claim 5.

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

8. The coolant system comprises: a cooler; a pump for circulating coolant around the controller and the motor and returning it to the cooler. The robotic vehicle according to claim 7.

9. The robotic vehicle according to claim 8, wherein the cooler is disposed above the motor. The robotic vehicle according to claim 8.

10. A robotic vehicle, comprising: a chassis including a right side and a left side; an operation unit located behind the chassis; a battery unit located 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 gearbox, A coolant system operably connected to the motor controller and the motor to dissipate heat from the motor controller and the motor, A right track assembly spaced apart from the right side of the chassis, A left track assembly spaced apart from the left side of the chassis, and Each of the right track assembly and the left track assembly includes a track motor operably connected to the track, A robotic vehicle.

11. The coolant system includes A cooler, and A pump for circulating coolant around the PTO motor controller and the PTO motor and returning it to the cooler, The robotic vehicle according to claim 10.

12. The PTO motor is disposed above the right track assembly and the left track assembly so as to dispose the PTO motor sufficiently away from the ground, The robotic vehicle according to claim 11.

13. Further including the output of the PTO motor disposed on the same plane above the PTO shaft, The robotic vehicle according to claim 12.

14. Each torque converter 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, The robotic vehicle according to claim 13.

15. The torque converter includes An output idler gear coupled to the PTO output gear, and An idler shaft axially coupled to the output idler gear, The robotic vehicle according to claim 14.

16. Each torque converter further includes a front plate, a mid plate, and a back plate for disposing the motor input gear above the input idler gear, disposing the PTO output gear adjacent to the input idler gear, and disposing the output idler gear above the PTO output gear, The robotic vehicle according to claim 15.

17. The torque converter further includes a front cover and a rear cover surrounding the front plate, the mid plate, and the back plate, The robotic vehicle according to claim 16.

18. The PTO motor controller is disposed in an operation unit behind the battery unit and above the PTO motor, The robotic vehicle according to claim 10.

19. ​ The torque converter further includes a motor input shaft coupled to the output of the PTO motor, The motor input shaft is disposed in the same plane above the PTO shaft such that the PTO motor extends away from the torque converter in the direction of the PTO shaft and toward the rear of the chassis, The robotic vehicle according to claim 14.

20. A single battery unit supplies power to the PTO motor and the track motors of the right track assembly and the left track assembly, respectively, The PTO motor operates independently of the track motors of the right track assembly and the left track assembly, respectively, The robotic vehicle according to claim 14.

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