Module Active Response System

Abstract

To provide a generator and a disc brake having a compact structure with respect to generation of energy in connection to a vehicle's disc brakes in combination with brushless electric motor-generators.SOLUTION: An energy generation system 200 has a generator 204, a mechanical coupler 206, a connecting member 208, and an energy storage system 210. The mechanical coupler is shown as a sprocket or gear having a plurality of teeth spaced apart on its circumference. The teeth are sized and shaped to engage corresponding ventilating slots 102 on a disc brake rotor 100.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] Cited Patent The entire texts of the following documents and references, namely, Erlston et al. (U.S. Patent Application No. 2008 / 0078631) and Bodenstein et al. (U.S. Patent Application No. 2012 / 0091724), are incorporated herein by reference.

[0002] The present invention relates to supplementally generating energy from the movement of a vehicle, and specifically to generating energy by combining a disc brake of a vehicle with a brushless electric generator.

Background Art

[0003] A large amount of energy is required to move a vehicle, and when the vehicle stops, approximately an equal amount of energy (minus transmission losses) is released. In recent years, in hybrid vehicles and other vehicles, an electric motor arranged on a wheel has been used to regenerate energy during braking. Similarly, a part of the energy used to move the vehicle can be recovered.

[0004] In vehicles equipped with disc brakes (e.g., automobiles, railway vehicles, light aircraft, and other similar applications), a rotor arranged on an axle or a wheel hub and a caliper mechanism are employed. The caliper mechanism presses brake pads against both sides of the rotor to generate friction and braking force. In most civilian and military aircraft, a plurality of rotors are connected to each other, and there are ventilation slots between the rotors. When a conventional disc brake is used, the kinetic energy of the vehicle is released as heat when the brake is applied.

Summary of the Invention

Problems to be Solved by the Invention

[0005] If electricity could be generated from such movement during braking, the battery would be charged and there would be no need to operate the vehicle's alternator, so there would be an advantage to such a function. What is required is a simple mechanical method for connecting to the brake rotor.

Means for Solving the Problems

[0006] The section of "Means for Solving the Problems" aims to outline some aspects of the present invention and is for briefly introducing some embodiments. To avoid the purpose of this section from being unclear, simplification or omission may be made in some cases. Such simplification or omission is not intended to limit the scope of the present invention.

[0007] References including patents or patent applications cited in this specification are all incorporated herein by reference. It is not admitted that any reference constitutes prior art. The content of the reference states the author's claims, and the applicant reserves the right to object to the accuracy and validity of the cited reference. Although multiple prior documents are referred to in this specification, it should be clearly understood that such references do not admit that any of the documents form part of the common general knowledge in the prior art.

[0008] It is recognized that the term "comprise" may be interpreted in either an exclusive or an inclusive sense under various jurisdictions. For the purposes of this specification, unless otherwise specified, the term "comprise" shall have an inclusive meaning. That is, it means including not only the listed components directly referred to, but also other components or elements not specifically shown. This principle also applies when the terms "comprised" or "comprising" are used in relation to one or more steps of a method or process.

[0009] In one aspect, the present invention relates to a vehicle energy device comprising a generator coupled to a shaft, said shaft having mechanical components for coupling to a disk ventilation slot and electronic components for connecting said generator to the vehicle's electrical system.

[0010] Other features and advantages of the present invention will become apparent by considering the following detailed description of its embodiments in conjunction with the accompanying drawings.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0012] The section "DETAILED DESCRIPTION OF THE INVENTION" is intended to outline some aspects of the present invention and to briefly introduce some embodiments. To avoid obscuring the purpose of this section, simplifications or omissions may be made. Such simplifications or omissions are not intended to limit the scope of the present invention.

[0013] To provide an overall understanding of the present invention, several exemplary embodiments and examples will be described below. However, it will be understood by those skilled in the art that different embodiments intended to be encompassed by the present disclosure may achieve the same or equivalent functions and sequences. The compositions, devices, systems, and / or methods described herein can be modified and altered to suit the particular application in view, and the ones described herein may be used in other suitable applications. Such other additions and modifications will not depart from the scope of the present disclosure.

[0014] To avoid obscuring the object of this section, simplification or omission may be made. Such simplification or omission is not intended to limit the scope of the present invention. References, including patents or patent applications cited herein, are hereby incorporated by reference in this specification. None of the references are admitted to constitute prior art. The content of the references states the claims of the authors, and the Applicants reserve the right to challenge the accuracy and validity of the cited documents. Although multiple prior documents are referred to in this specification, it should be clearly understood that such references do not recognize that any of the documents form part of the common general knowledge in the prior art.

[0015] As used in this specification and the claims, the singular forms "a", "an", and "the" include the plural unless the context clearly indicates otherwise. For example, the term "a transaction" can include multiple transactions unless the context clearly indicates otherwise. As used in this specification and the claims, the names or types referred to in the singular form include the variations subsumed by that name unless the context clearly indicates otherwise.

[0016] In the following description, there are also terms used for convenience only, and these terms are not limiting. The terms "lower", "upper", "bottom", "top", "front", "back", "left", "right", and "sides" indicate the directions referred to in the figures, but do not limit the directions in which the modules or any of their assemblies can be used.

[0017] The term "comprise" has been recognized as being potentially interpretable in various jurisdictions as having either an exclusive or an inclusive meaning. For the purposes of this specification, unless otherwise specified, the term "comprise" shall have an inclusive meaning. That is, it is meant to include not only the recited components directly referred to, but also other components or elements not specifically shown. This principle also applies when the terms "comprised" or "comprising" are used in relation to one or more steps of a method or process.

[0018] Referring to FIG. 1, a disk brake system currently in practical use in the prior art is shown together with a disk brake rotor 100. The disk brake rotor 100 has ventilation slots 102 arranged circumferentially around its center. A brake caliper 104 with a hollow interior defined by a pair of side portions 106, 108 is arranged so as to straddle the disk brake rotor 100. Inside the hollow interior on the inner sides of the side portions 106, 108 are a pair of brake pads 110 sized to mesh with a part of the outer surface of the disk brake rotor 100. The brake caliper 104 is tightened by a guide pin 112 arranged at one end of the brake caliper 104, thereby moving the brake pads 110 so that the brake pads 110 can mesh with the disk brake rotor 100. The brake pads 110 can be visually inspected through an inspection hole 114 at the top of the brake caliper 104 to determine the relative wear of the pads. The disk brake rotor 100 is connected to the wheel via a wheel hub 116 and wheel studs 118. Although the disk brake rotor is illustrated and disclosed here, it is to be understood that the energy generation system of the present invention includes, but is not limited to, drum brakes and may be used in combination with other components that can be attached or coupled to the vehicle axle (i.e., rotate with the tire). When using other components, it can be understood that it can be customized so that a chain or other rotating conveyor can be wound around and meshed with the components to achieve energy generation as disclosed herein.

[0019] Referring to FIGS. 2 - 37, various embodiments of an energy generation system 200 are shown as having a generator 204, a mechanical coupler 206, a connection member 208, and an energy storage system 210. In both the front wheel configuration and the rear wheel configuration, the system 200 fits within the wheel area and can rotate in accordance with the movement of the wheel if it is located on the front side.

[0020] Referring to FIGS. 2, 3, 21, and 29A - C, the mechanical coupler 206 is shown as a sprocket or gear having a plurality of teeth 212 spaced around its circumferential surface. These teeth 212 are sized and shaped to mesh with corresponding ventilation slots 102 of the disk brake rotor 100. In another embodiment (FIGS. 33 - 37), the coupler 206 meshes with an opening of a roller chain 300 disposed around the edge of the disk brake rotor 100 to facilitate rotation. Referring to FIG. 19, in order to facilitate the mechanical connection of the chain 300 to the disk brake rotor 100, the spokes or elongated members 214 forming the ventilation slots 102 are provided with tapered ends 216 for meshing with the openings of the links of the chain 300. Also, although a chain is illustrated and disclosed here, it will be understood that other rotating conveyors such as timing belts and pulleys may be used, but are not limited to these. Further, although tapered ends are illustrated and disclosed here, it will be understood that the chain or other rotating conveyor may be meshed with the disk brake rotor 100 by friction or other known connectors 336 or connection methods. In particular, referring to FIG. 30A, various connectors can be fixed or disposed in a channel 340 provided around the disk brake rotor 100.

[0021] The mechanical coupler 206 is connected to a shaft or axle 208 passing through its center. A bracket 202 can be used to maintain the coupler 206 in an appropriate position relative to the disk brake rotor 100. Similar to the disk caliper 104 during operation, the bracket 202 is maintained parallel to the surface of the disk brake. To prevent interference with the operation of the disk brake, the coupler 206 and the bracket 202 are disposed away from the caliper 104 around the disk brake rotor 100.

[0022] Referring back to FIG. 2, the bracket 202 with a hollow interior defined by a pair of side walls 220 is arranged to straddle the disk brake rotor 100. Opposing holes 222 for receiving a portion of the axle or shaft 208 are provided through the side walls 220 to enable alignment of the coupler 206 with the ventilation slot 102. As shown in FIG. 16, a bush 224 may be inserted into the hole 222 to facilitate rotation of the axle 208.

[0023] The axle 208 is connected to a generator 204 for generating energy in either alternating current (“AC”) or direct current (“DC”) form. This energy is transmitted and / or stored in an energy storage unit or system. The energy storage unit or system may be located locally with the generator or may be part of the vehicle's energy system. This may include power supply to an alternator / battery bus and / or separate vehicle electronic circuits. For example, the energy can be stored in one or more batteries and / or trailers or their accessories disposed on the vehicle.

[0024] Now referring to FIGS. 13, 23, 24, 27, 28, 31 - 33, the energy generation system 200 may include a clutch 230 to generate energy only when desired or necessary. The illustrated positive clutch 230 includes a jaw member 232 at the end of the axle 208 and a corresponding jaw member 234 disposed on the driven shaft 236 for the generator 204. When the clutch 230 engages, the corresponding jaw members 232, 234 engage and rotational motion can be transmitted to the generator 204. When the engaged state is released, the axle 208 rotates without transmitting energy to the generator 204. Similarly, since the generation of energy can be electronically shunted, the load when no energy is being generated is minimized.

[0025] During operation, one or more teeth 212 of the sprocket 206 engage with each slot of the ventilation slots 102 of the disc brake rotor 100. When the disc brake rotor 100 rotates, the teeth 212 of the sprocket 206 move and disengage from or engage with the slots 102, so the sprocket 206 and the axle 208 also rotate. In this way, when the wheel moves, the disc brake rotor 100 moves and the axle 208 leading to the generator moves, generating energy stored in the vehicle. If necessary, the clutch 230 may be utilized to selectively enable control of the energy transmission to the generator 204.

[0026] Figures 11 - 20 show another embodiment of the present invention that uses a chain 300 to transmit rotational energy from the disc brake rotor 100 to a coupler or sprocket 206. In this embodiment, the sprocket 206 is offset from the disc brake rotor 100. As shown in Figures 19 and 20, the ventilation slots 102 are formed by a plurality of spokes or elongated members 214 having tapered ends 216. The chain 300 extends over a substantial portion of the circumferential surface of the disc brake rotor 100 that engages the tapered ends 216 and a portion of the sprocket 206, thereby engaging with the teeth 212 of the sprocket. Referring to Figure 14, the clutch 230 as disclosed above may be used to selectively control the energy transmission to the generator 204.

[0027] It should be noted that, in closing this detailed description, it will be apparent to those skilled in the art that many changes and modifications can be made to the embodiments without substantially departing from the principles of the present invention. Also, such changes and modifications are intended to be included within the scope of the present invention as set forth in the appended claims. Further, in the following claims, all means or step - plus - function elements in terms of structure, materials, acts, and equivalents are intended to include any structure, material, or act for performing their recited functions.

[0028] It should be emphasized that the above-described embodiments of the present invention, particularly the "proposed embodiments", are merely examples of feasible implementations shown only for clearly understanding the principles of the present invention. Without substantially departing from the intent of the principles of the present invention, any changes and modifications may be made to the above-described embodiments of the present invention. All such modifications and changes are intended to be included within the scope of this disclosure and the present invention and are protected by the following claims.

[0029] The present invention has been described in sufficient detail to a certain extent. Their usefulness is understood by those skilled in the art. It is understood by those skilled in the art that the present disclosure of these embodiments is only an example, and various changes in the arrangement and combination of components may be adopted without departing from the intent and scope of the present invention as claimed. Therefore, the scope of the present invention is defined not by the description of the above-described embodiments but by the appended claims.

Claims

1. A system for generating energy in a vehicle having a disc brake including a disc with a plurality of ventilation slots provided on its circumferential surface, a generator, a coupler having a plurality of teeth for mechanically connecting the generator to the ventilation slots of the disc, and a bracket for holding the coupler in a position where the teeth engage with the ventilation slots of the disc. The system wherein rotation of the disc rotates the coupler to supply rotational energy for generating energy for storage to the generator.

2. The system according to claim 1, wherein the generator includes a connecting member for mechanically connecting the generator to the coupler.

3. The system according to claim 2, wherein the connecting member is an axle.

4. The system according to claim 2, wherein the coupler includes a coupler member having a plurality of teeth for engaging with the ventilation slots.

5. The system according to claim 2, further including a bracket for maintaining the coupler in place with respect to the ventilation slots of the disc.

6. The system according to claim 1, wherein the coupler includes a coupler member having a plurality of teeth for engaging with the ventilation slots.

7. The system according to claim 1, wherein the coupler includes a chain disposed around at least a portion of the circumferential surface of the disc and a coupler member having a plurality of teeth for engaging with the chain.

8. The system according to claim 7, wherein the ventilation slots of the disc are defined by an elongated member having a tapered end, and the chain engages with the tapered end of the elongated member.

9. The system according to claim 1, further including a bracket for maintaining the coupler in place with respect to the ventilation slots of the disc.

10. The system according to claim 1, wherein the coupler includes a chain.

11. The system according to claim 1, further including a clutch for selectively controlling the generation of energy by the generator.

12. The system according to claim 1, further including an energy storage system electrically connected to the generator for storing the energy generated by the rotation of the disc. A system for generating energy in a vehicle having a disc brake including a disc provided with a plurality of ventilation slots on its circumferential surface, comprising: a generator; a chain having a plurality of links disposed at at least a part of the circumference of the disc and having through openings; a coupler having a plurality of members for engaging with the openings of the plurality of links of the chain; at least one connecting member for mechanically connecting the generator to the coupler, wherein rotation of the disc rotates the coupler and the connecting member to supply rotational energy for generating energy for storage to the generator. **Claim 14** The system according to claim 13, wherein the plurality of members are teeth. **Claim 15** The system according to claim 13, further comprising a bracket for maintaining the coupler in place with respect to the disc brake of the disc. **Claim 16** The system according to claim 13, further comprising a clutch for selectively controlling the generation of energy by the generator. **Claim 17** The system according to claim 13, wherein the coupler includes a chain disposed around at least a part of the circumferential surface of the disc and a coupler member having a plurality of teeth for engaging with the chain. **Claim 18** A system for generating energy in a vehicle having a disc brake including a disc provided with a plurality of ventilation slots on its circumferential surface, comprising: a generator; a chain having a plurality of links disposed at at least a part of the circumference of the disc and having through openings; a coupler having a plurality of members for engaging with the openings of the plurality of links of the chain; at least one connecting member for mechanically connecting the generator to the coupler, wherein rotation of the disc rotates the coupler and the connecting member to supply rotational energy for generating energy for storage to the generator, wherein the coupler includes a chain disposed around at least a part of the circumferential surface of the disc and a coupler member having a plurality of teeth for engaging with the chain, wherein the ventilation slots of the disc are defined by elongated members having tapered ends, and the chain engages with the tapered ends of the elongated members. **Claim 19** The system according to claim 13, further comprising an energy storage system electrically connected to the generator for storing energy generated by the rotation of the disk.

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