High-efficiency powertrain system for long-range electric vehicles

Abstract

High-Efficiency Powertrain System for Long-Range Electric Vehicles is advanced powertrain technology for electric vehicles that integrates battery (1) electrically coupled to motor (3) via transformer (2a), which multiplies the minimal voltage supplied by battery (1) to meet motor's (3) requirements. This efficient energy utilization ensures battery (1) maintains higher state of charge, thereby extending its operational range. The motor (3) is mechanically coupled to alternator (4), which performs dual functions: transferring mechanical rotation to multi-speed gearbox (5) and generating electricity to recharge battery (1). This continuous recharging process allows the battery (1) to remain at maximum voltage, substantially increasing its lifespan and vehicle's range, reaching up to 10,000 kilometres on single charge. In the event of battery discharge, SEPT (6) with another identical transformer (2b) rapidly recharges the battery (1), allowing for quick resumption of vehicle operation. This adaptable powertrain can be integrated into two-wheelers, three-wheelers, and four-wheelers, with optimized component placement for each configuration.

Description

[0001] Title of Invention

[0002] High-Efficiency Powertrain System for Long-Range Electric Vehicles

[0003] Field of Invention

[0004] The present novel invention relates to the technical field of mechanical as well as electrical, more particularly to a kind of self-charging electric vehicle with unique powertrain technology to increase the range in all kinds of electric vehicles (2 Wheelers, 3 Wheelers and all type of 4 Wheelers [from passenger to construction to defensive vehicles, and other heavy load vehicles]) while the electric vehicles are in motion and / or in stationary without installing additional battery banks.

[0005] Background of Invention

[0006] As the world grapples with the escalating threat of climate change, rising emissions, and environmental degradation, electric vehicles (EVs) have emerged as a beacon of hope. With the global automotive sector accounting for a significant share of greenhouse gas emissions, the transition to EVs is critical for mitigating the environmental impact of transportation. Developing countries, in particular, are experiencing rapid growth in their automotive and industrial sectors, making the adoption of sustainable transportation solutions a pressing imperative.

[0007] Electric vehicles offer several advantages over traditional petroleum vehicles. For instance, they produce no tailpipe emissions, reducing air pollution and greenhouse gas emissions that contribute to climate change. Additionally, EVs operate quietly, reducing noise pollution and creating a more pleasant driving experience. Furthermore, EVs can be powered by renewable energy sources, such as solar or wind power, reducing dependence on fossil fuels. Moreover, EVs have lower operating costs compared to petroleum vehicles, with reduced fuel and maintenance expenses. Despite the advantages of EVs, there are several limitations that need to be addressed. One of the major hurdles is the limited range of EVs, typically between 200-300 miles, before needing to be recharged. Moreover, EVs are often more expensive than petroleum vehicles, although costs are decreasing as technology improves. The scarcity of recharging facilities and lengthy recharging times can also make long-distance travel challenging. Furthermore, EVs require large, heavy batteries, which can affect vehicle performance and reduce efficiency.

[0008] The environmental benefits of EVs are undeniable. By reducing greenhouse gas emissions and air pollution, EVs can help mitigate climate change. They can also improve air quality in urban areas, improving public health and quality of life. Moreover, EVs can reduce dependence on fossil fuels, conserving natural resources for future generations. As the world transitions to a more sustainable energy future, electric vehicles will play a critical role in reducing emissions, improving air quality, and conserving natural resources.

[0009] To overcome the barriers to EV adoption, innovative solutions are being developed. Interchangeable batteries, for instance, can reduce recharging times and increase driving range. Fast charging technologies can also reduce recharging times to under 30 minutes. New battery technologies, such as solid-state batteries, can improve range and efficiency. Moreover, governments and companies are investing in the development of extensive charging networks, making it easier for people to own and operate EVs.

[0010] As technology continues to evolve, EVs are likely to become increasingly viable alternatives to petroleum vehicles. With ongoing innovations in battery technology, charging infrastructure, and vehicle design, the limitations of EVs are being addressed. The future of transportation is electric, and it's essential that we continue to invest in and develop sustainable transportation solutions to mitigate the environmental impact of transportation and create a more sustainable future for generations to come.

[0011] An invention disclosed in patent application number US2010184560A1 discloses a model that have purpose of the present invention is to provide a supplementary power source to the electric motor in times of high current demand, such as accelerating the vehicle. Generally, the electric vehicle is powered by one or more sets of battery banks connected to an electric motor in series. The electric current is controlled and distributed through a system from the battery banks to the electric motor. The battery banks are formed by a plurality of batteries connected in series and each bank has a positive and negative terminal to deliverthe available current to the electric motor. Voltage and current being delivered to the electric motor from the battery banks is monitored and if the one or both of these levels falls below a predetermined level, the current draw may be switched from the charge depleted battery bank to the backup bank (likely a fully charged battery bank). If the electric motor demands more current than what the battery banks are able to deliver for a short amount time, a capacitor bank is available to assist as a supplementary power source to the electric motor. This is particularly beneficial during times of vehicle acceleration where the current draw from the motor is highly elevated. The ability to switch between a charge depleted battery bank and a fully charged battery bank helps to overcome the current issue of electric vehicles typically traveling less than 100 miles. By having two or more battery banks onboard the electric vehicle, a car assembled in accordance with at least some embodiments of the present invention will be adapted to travel between about 150 and 200 miles in the city or between about 350 and 600 miles on the highway on a single charge when both battery banks are fully charged. The inclusion of a capacitor bank helps to overcome the lack of power associated to electric vehicles during times of quick acceleration. The capacitor bank stores a charge delivered from the power source and releases it when the demand of the electric motor necessitates an increase in current to handle the load from the vehicle's transmission. The integration of these two features into an electric vehicle permits the vehicle to become more long range in traveling distance and provides increased power to the vehicle during times of acceleration.

[0012] An invention disclosed in patent application number CH633751A discloses a vehicle which comprises of two motors controlled by means of a regulator by a speed selector and by a contactor actuated by the brake pedal. The motors are connected to a bank of accumulators capable of being recharged from the electric mains or by panels of photo-electric cells or by an electricity generating set if the need arises. A traction selector makes it possible to choose one of the motors for propelling the vehicle. The other motor is intended to operate as a generator and is capable of being coupled to the wheels when the vehicle is slowing down and requiring a slowing force greater than that supplied by the propulsion motor operating as a generator. The energy recovered by the two motors operating as generators is used for recharging the bank of accumulators.

[0013] An invention disclosed in patent application number IN202141050704A discloses a battery system. In this Battery system while increasing the Electric vehicle life and Mileage, it also, increases the Battery life and life cycle. This system contains two Battery and one alternator (Specification of alternator and Battery will differ as per requirement). This circuit works with three switching units, one switch control, the motor controller, and other two are connected with Battery's for selection. When the vehicle is running, motor controller is connected with one Battery and at the same time another battery gets charge from alternator. This battery switches are interlocked with each other such that, we can't charge and discharge the Battery at the same time. Alternator is connected with motor. Alternator power passes through isolation transformer and this power will be converted with rectifier unit then will go to charging unit. Charging condition is controlled by Battery selection switches.

[0014] The novel invention introduces a powertrain assembly that enhances the charging and performance of electric vehicles, reducing their reliance on traditional energy storage devices and motors. This innovative system extends the range of two- and four-wheelers to up to 10,000 km per charge using a standard battery pack, eliminating the need for multiple battery banks. By generating and converting energy while the vehicle is in motion, it minimizes the necessity for frequent charging points or outlets.

[0015] The present novel powertrain technology enables the vehicle to self-charge until the battery is fully depleted, operating silently and significantly increasing the range of electric vehicles. Furthermore, it boosts battery efficiency and longevity, extending its lifespan from approximately 3 years to up to 9 years.

[0016] In normal operation, the power flow in the powertrain is from battery to motor according to command from driver, through transformer, which makes sure that battery gets discharged minimal, then this electrical power is converted into mechanical power. Which drives alternator and gearbox. Then power is transferred to wheels from differential. (Battery -> Transformer -> Motor -> Alternator -> Gearbox -^Wheels). When the motor drives the alternator, it produces current that is supplied back to the battery, maintaining its charged state. When the battery gets discharged, there is no need to wait for charging, as there is a Separate Electric PowerTerminal (SEPT) which charges battery. The power will flow to battery from charging cell through another identical transformer (Charging cell -> Transformer -> Battery), when battery get certain amount of current to drive gearbox and alternator, this will generate current and supply to battery, adding charging current making electric loop complete, and vehicle will run as usual on previous power flow cycle. This setup can increase the vehicle's range and downtime by thousands of kilometres and up to 5 minutes respectively, making frequent charging, power stations unnecessary and ensuring prolonged operation.

[0017] The present unique electric powertrain technology can be applied to various electric vehicles, including two, three, and four-wheelers, without requiring battery replacement for about 8 to 9 years due to improved battery efficiency. It also reduces the number of batteries needed, making the vehicle lighter.

[0018] Objectives of the invention

[0019] • Principal objective of the present novel invention is to develop a powertrain assembly that enhances the charging and performance of electric vehicles, thereby reducing their dependence on traditional energy storage devices and motors, which eliminate the need for frequent charging points or outlets by generating and converting energy while the vehicle is in motion, and significantly improve battery efficiency and lifespan, extending it from approximately 3 years to up to 9 years.

[0020] • Further objective of the present novel invention is to enhance the driving range of electric vehicles to address range anxiety and increase the practicality of electric mobility for daily commuting and long-distance travel.

[0021] • Another objective of the present novel invention is to enhance vehicle performance by optimizing acceleration, top speed, and uphill capabilities, making electric vehicles competitive with traditional internal combustion engine vehicles. • Further objective of the present novel invention is to optimize powertrain efficiency to minimize energy consumption during operation, thereby maximizing the utilization of onboard battery capacity and extending driving range.

[0022] • Another objective of the present novel invention is to reduce reliance on fossil fuels and mitigate environmental impacts by transitioning towards electric mobility solutions powered by renewable energy sources.

[0023] • Further objective of the present novel invention is to minimize fuel expenses and maintenance costs associated with electric vehicles compared to traditional combustion engine vehicles, resulting in long-term cost savings for vehicle owners.

[0024] • Another objective of the present novel invention is to accelerate the widespread adoption of electric vehicles by addressing technical limitations, enhancing performance, and improving overall value proposition for consumers.

[0025] • Further objective of the present novel invention is to support the expansion of charging infrastructure to increase accessibility and convenience for electric vehicle owners, promoting the growth of the electric mobility ecosystem.

[0026] • Another objective of the present novel invention is to foster innovation in electric vehicle technology and powertrain design to continually improve efficiency, performance, and sustainability, driving progress towards a greener and more sustainable transportation sector.

[0027] • Still another objective of the present novel invention is to prioritize safety and reliability in powertrain design and operation to instil confidence in electric vehicle technology and ensure a positive experience for drivers and passengers alike.

[0028] Summary

[0029] The present novel powertrain design is set to transform the electric vehicle (EV) landscape, offering unparalleled efficiency, performance, and range. With a range of up to 10,000 km on a single charge, this innovative technology is redefining the possibilities of electric mobility. The powertrain's intelligent energy management system and meticulous component integration work in harmony to deliver seamless operation and extended driving capabilities. In normal operation, the power flow begins from the battery, which supplies power to the motor via a transformer, expertly modulating voltage and current to optimize motor performance. The alternator generates electrical power to recharge the battery, ensuring the battery maintains a charged state, enhancing overall efficiency and extending the driving range.

[0030] The sophisticated gearbox further optimizes performance, increasing top speed and uphill capabilities to make the EV suitable for diverse driving conditions. When the battery is discharged, a cutting-edge Separate Electric Power Terminal (SEPT) rapidly recharges it in just 5 min, minimizing downtime and ensuring the EV can quickly resume normal operation. This adaptable design allows for integration into existing EV models with some modifications, promising not only increased range and performance but also enhanced reliability and sustainability. By combining advanced engineering with practical innovation, this powertrain design offers a viable solution for extending the range and performance of electric vehicles, aligning with the growing demand for sustainable and efficient transportation. With its potential to revolutionize the electric mobility landscape, this technology is poised to pave the way for a new era in electric mobility, where electric vehicles can achieve unprecedented levels of efficiency, reliability, and performance.

[0031] List of Drawings:

[0032] Figure 1: Block diagram of Powertrain technology

[0033] Figure 2: Powertrain technology in two wheelers

[0034] Figure 3: Powertrain technology in three wheelers

[0035] Figure 4: Powertrain technology in four wheelers

[0036] List of the Components:

[0037] 1. Battery

[0038] 2. Transformer (2a)

[0039] 3. Motor 4. Alternator

[0040] 5. Gearbox

[0041] 6. SEPT (Separate Electric Power Terminal)

[0042] 7. Transformer (2b)

[0043] Detailed Description of Drawing and Invention

[0044] The present novel invention High-Efficiency Powertrain System for Long-Range Electric Vehicles has Battery (1), Transformer (2a), Motor (3), Alternator (4), Gearbox (5), Charging Cell / SEPT (6), Transformer (2b).

[0045] Figure 1 illustrates the block diagram of the powertrain technology, which enables any electric vehicle (EV) to achieve an increased range of up to 10,000 kilometres, surpassing conventional electric vehicles that rely solely on batteries (1) or other energy storage systems as their power source. The present novel embodiment features a sophisticated integration of components designed to optimize energy usage and extend the vehicle's operational range significantly.

[0046] In the present novel powertrain system, the battery (1) is electrically coupled to the motor (3) through a transformer (2a). The battery (1) supplies a minimal voltage, which the transformer (2a) then multiplies to meet the motor's (3) required voltage. This transformation process is crucial as it allows the battery (1) to maintain a higher state of charge, effectively extending its range. The motor (3), once powered, drives the alternator (4) that is mechanically coupled to it. The alternator (4) generates electrical voltage during the motor's (3) operation, which is then fed back into the battery (1). This continuous generation and supply of electric voltage to the battery (1) ensure that it remains in a charged state, thereby prolonging the battery's (1) lifespan and enhancing the vehicle's overall range. Consequently, the range of the electric vehicle can reach up to 10,000 kilometres on a single charge without the need for additional batteries, revolutionizing EV efficiency and performance.

[0047] The shaft of the motor (3) begins to rotate using the electrical energy supplied by the battery (1). The torque generated by the rotations of the motor's (3) shaft is transferred to the alternator (4). The alternator (4), in turn, transfers torque to the gearbox (5) or belt drive, thereby rotating the axle of the wheels. The rotation of the axle shaft drives the wheels, propelling the vehicle. The gearbox (5) is a multi-speed system designed to provide higher torque at initial gears and higher speed at subsequent gears. The initial gears facilitate torque and power multiplication, allowing the motor (3) to operate at low power while maintaining sufficient torque at the wheels. When the vehicle needs to reach top speed, the higher gears come into play, enabling high-speed operation and enhancing the vehicle's top speed.

[0048] In scenarios where the battery (1) gets discharged, the present novel powertrain also incorporates a state-of-the-art SEPT (Separate Electric Power Terminal) (6) technology that directs power from the charging cell through the transformer (2b) to the battery (1), ensuring rapid and efficient recharging. The powertrain utilizes a (SEPT) (6). The SEPT (6) provides a certain amount of voltage to the battery (1) through transformer (2b), charging it up to a specific level based on the cell's maximum voltage capacity. Once the battery (1) reaches this charge level, it can propel the vehicle, causing the alternator (4) to rotate and generate electricity. This generated electricity is supplied back to the battery (1), completing the electric loop. This loop ensures that the battery (1) starts recharging, as the voltage supplied by the alternator (4) is higher than the discharged voltage of the battery (1).

[0049] This dual power flow system, normal operation and discharged state, ensures that the vehicle can resume operation quickly and efficiently, minimizing downtime. The adaptable design allows for integration into existing electric vehicle platforms with some modifications. These modifications primarily involve accommodating the transformer (2a & 2b), alternator (4), and the gearbox (5) within the vehicle's existing framework, enhancing performance, reliability, and range.

[0050] The present novel powertrain represents a significant advancement in electric vehicle technology, offering a practical solution for extending range and improving efficiency. By integrating the present novel powertrain, electric vehicles can achieve unprecedented levels of efficiency, reliability, and performance, paving the way for a new era of sustainable transportation. Figure 2 illustrates the powertrain technology in two-wheelers. The power flow follows the same sequence as explained in the flow chart (Figure 1). In the present novel configuration, the battery (1) provides power to the motor (3) through a transformer (2a). The transformer (2a) multiplies the voltage from the battery (1) to meet the motor's (3) requirements, ensuring efficient energy use.

[0051] The motor (3), once powered, drives the alternator (4). The alternator (4) performs dual functions: it transfers mechanical rotation to the gearbox (5) and simultaneously generates electricity, which it transfers back to the battery (1). This continuous generation of electricity helps maintain the battery's (1) charge.

[0052] Once the gearbox (5) receives power from the alternator (4), it transfers this power to the wheels, thereby propelling the vehicle. This integrated system ensures efficient power utilization and extends the range of the two-wheeler, leveraging the continuous recharging of the battery (1) by the alternator.

[0053] Figure 3 illustrates the powertrain technology in three-wheelers. The functionality of the powertrain remains the same, with differences only in the placements of the components to fit the three-wheeler configuration. The power flow follows the same sequence as explained in the flow chart.

[0054] In this configuration, the battery (1) provides power to the motor (3) through a transformer (2a). The transformer (2a) multiplies the voltage from the battery (1) to meet the motor's (3) requirements, ensuring efficient energy use.

[0055] The motor (3), once powered, drives the alternator (4). The alternator (4) performs dual functions: it transfers mechanical rotation to the gearbox (5) and simultaneously generates electricity, which it transfers back to the battery (1). This continuous generation of electricity helps maintain the battery's (1) charge.

[0056] Once the gearbox (5) receives power from the alternator (4), it transfers this power to the wheels, thereby propelling the vehicle. This integrated system ensures efficient power utilization and extends the range of the three-wheeler, leveraging the continuous recharging of the battery (1) by the alternator (4). The placement of components is optimized to fit within the unique spatial constraints of a three-wheeler, ensuring both functionality and compactness.

[0057] Figure 4 illustrates the powertrain technology in four-wheelers. The functionality of the powertrain remains the same, with differences only in the placements of the components to fit the four-wheeler configuration. The power flow follows the same sequence as explained in the flow chart (Figure 1).

[0058] In this configuration, the battery (1) provides power to the motor (3) through a transformer (2a). The transformer (2a) multiplies the voltage from the battery (1) to meet the motor's (3) requirements, ensuring efficient energy use.

[0059] The motor (3), once powered, drives the alternator. The alternator (4) performs dual functions: it transfers mechanical rotation to the gearbox (5) and simultaneously generates electricity, which it transfers back to the battery (1). This continuous generation of electricity helps maintain the battery's (1) charge.

[0060] Once the gearbox (5) receives power from the alternator (4), it transfers this power to the wheels, thereby propelling the vehicle. This integrated system ensures efficient power utilization and extends the range of the four-wheeler, leveraging the continuous recharging of the battery (1) by the alternator (4).

[0061] The placement of components is optimized to fit within the spatial constraints of a four- wheeler, ensuring both functionality and compactness.

[0062] According to one embodiment of the present novel invention, the motor (3) is selected from the group consisting of AC / DC brushless motor, dielectric motor, induction motor, permanent magnet motor, permanent magnet synchronous motor, synchronous reluctance motor and a switched reluctance motor.

[0063] According to an embodiment of the present novel invention, at least one power storage device / Battery (1) selected from Lithium-Ion (Li-Ion), NMC (Nickel Manganese Cobalt), LFP (Lithium Iron Phosphate), NCA (Nickel Cobalt Aluminum), Solid-State, Nickel-Metal Hydride (NiMH), Lithium-Polymer (LiPo), Lithium-Manganese Oxide (LMO), Nickel-Cadmium (NiCd), Sodium-lon, Zinc-Air, Lead-Acid, Advanced Lead-Acid (AGM), Hydrogen Fuel Cells, Vanadium Redox Flow, Redox Flow, Lithium Titanate (LTO), Sodium-Sulphur (NaS), Zinc-Bromine, and Lithium-Sulphur (Li-S). However, any battery, which is a type of electrical storage unit, is well within the scope and ambit of the present invention.

[0064] The system is completely pollution-free and environment friendly. In this specification, the terms "electric vehicle," "hybrid vehicle," "vehicle," and "automobile" encompass passenger cars, battery-powered vehicles, road traffic vehicles, heavy cargo vehicles (HCV), buses, twowheeled vehicles, E-Rickshaws, electric bicycles, electric scooters, electric motorcycles, tricycles, electric wheelchairs, construction vehicles, military vehicles, trains, and mining vehicles.

[0065] The present novel powertrain design offers a significant range of technical advantages. It enables an electric vehicle to achieve an impressive range of up to 10,000 kilometres on a single charge, far surpassing conventional electric vehicles. This is achieved through efficient energy utilization, as the transformer (2a) multiplies the voltage from the battery to meet the motor's requirements, maintaining a higher state of charge and extending the battery's (1) lifespan. The alternator (4) continuously generates electricity, supplying it back to the battery (1) and ensuring continuous charging. The multi-speed gearbox (5) provides high torque at initial gears for acceleration and high speed at higher gears, optimizing performance. The powertrain can integrate various types of batteries (1), allowing flexibility in energy storage solutions. The Separate Electric Power Terminal (SEPT) (6) quickly recharges the battery (1) through another identical transformer (2b) in case of discharge, minimizing downtime. The design is adaptable to two-wheelers, three-wheelers, and four-wheelers with component placement adjustments, making it versatile for various electric vehicles. By enhancing overall efficiency, improving battery (1) lifespan, and offering better acceleration, range, and speed capabilities, this powertrain promotes sustainable transportation. Additionally, its extended range and improved battery lifespan can reduce the overall cost of ownership. The innovative charging cell technology ensures quick recharging for reliability and user convenience. Overall, this powertrain represents a highly efficient, versatile, and reliable solution for modern electric vehicles, offering substantial improvements over conventional designs.

[0066] The embodiments presented herein and their various features and advantageous features are explained with reference to non-limiting embodiments in the following description. Descriptions of well-known components and methods of operation have been omitted so as not to unnecessarily obscure the present embodiments. The examples used herein are only intended to facilitate understanding of the ways in which the present embodiments may be practiced, and to further assist those skilled in the art to practice the disclosed embodiments. Accordingly, the examples should not be construed as limiting the scope of the presented invention.

[0067] In the foregoing description of specific embodiments, the general idea of the presented embodiments has been disclosed so fully that, using known knowledge, others can easily modify and / or adapt such specific embodiments for different applications without departing from the general concept and, therefore, such adaptations and modifications can and is to be understood as falling within the meaning and range of equivalents of the disclosed embodiments. It should be understood that the language or terminology used in this document is for the purpose of description and not limitation. Therefore, although the options presented.

[0068] The numerical values mentioned for various physical parameters, dimensions or quantities are only approximate, and it is assumed that values that are greater / less than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the present invention, unless the description statements indicate otherwise.

[0069] Example 1:

[0070] The testing of the novel powertrain conversion involved upgrading an existing electric vehicle (EV) with a 12V battery (1), a transformer (2a) with 1000 turns, a motor (3) requiring 400V, and an alternator (4) producing 12V. The battery supplies minimal voltage, which is then multiplied by the transformer (2a) to meet the motor's (3) required amount, effectively extending the battery's (1) range. The motor (3), powered by the transformer's (2a) voltage multiplication, drove the alternator (4), which performed dual functions: it transferred mechanical rotation to the gearbox (5) and generated electricity to continuously recharge the battery (1), maintaining a constant voltage. The gearbox (5), with gear ratios of 3.41, 2.29, 1.39, 0.87, 0.58, and 0.35, along with a differential gear ratio of 3.41, effectively transferred power to the wheels. The vehicle, weighing 1652 kg, achieved a top speed of 244 km / h, climbed a gradient angle of 53 degrees, and demonstrated an acceleration of 7 m / s2. The powertrain theory, involving efficient voltage transformation and continuous recharging, ensured optimal energy utilization and superior driving capabilities. The test confirmed the powertrain's efficiency, showing significant performance enhancements with constant battery (1) voltage, excellent acceleration, and gradient handling, validating the novel powertrain's effectiveness and reliability for modern electric vehicles.

[0071] Example 2:

[0072] In this test, we converted an existing electric vehicle with a 6V battery (50% charge) to the novel powertrain design. The battery's (1) voltage was increased to 400V using a transformer (2a) with 1000 turns to meet the motor's (3) requirements. The motor (3) drove an alternator (4) that produced 12V, continuously recharging the battery (1) and helping it maintain a higher state of charge. The vehicle's gearbox (5), with gear ratios of 3.41, 2.29, 1.39, 0.87, 0.58, and 0.35 for the 1st to 6th gears respectively, and a differential gear ratio of 3.41, efficiently transferred power to the wheels. The vehicle, weighing 1652 kg, achieved a top speed of 244 km / h, demonstrated excellent acceleration of 7 m / s2, and successfully handled a gradient angle of 53 degrees. Despite starting with a battery (1) at 50% charge, the continuous recharging from the alternator (4) ensured stable performance and gradually brought the battery (1) voltage back to its maximum of 12V, validating the powertrain's efficiency in maintaining battery (1) health and vehicle performance.

[0073] Example 3:

[0074] In this test, we converted an existing electric vehicle with a fully discharged battery (1) to the novel powertrain design. Initially, the battery (1) had minimal voltage, so the Separate Electric Power Terminal (SEPT) (6) came into play. The charging cell in SEPT (6) provided voltage to the battery through another identical transformer (2b), allowing the motor (3) to start. As the motor (3) operated, it drove the alternator (4), which produced 12V and began recharging the battery (1). With the battery (1) now having sufficient charge to run the motor (3), the electric loop became complete and self-sufficient. The alternator continued to generate 12V, supplying it back to the battery (1). This continuous charging ensured that the battery (1) voltage gradually increased to its maximum of 12V. The vehicle's gearbox (5), with gear ratios of 3.41, 2.29, 1.39, 0.87, 0.58, and 0.35 for the 1st to 6th gears respectively, and a differential gear ratio of 3.41, efficiently transferred power to the wheels. The vehicle, weighing 1652 kg, achieved a top speed of 244 km / h, demonstrated excellent acceleration of 7 m / s2, and successfully handled a gradient angle of 53 degrees. This test demonstrated the powertrain's capability to recover and maintain stable performance even with an initially discharged battery (1), ultimately bringing the battery (1) voltage back to its maximum of 12V through continuous charging from the alternator (4).

[0075] Dated: Wednesday, 18thSeptember, 2024

[0076] Mr. Amitkumar Patel

[0077] Patent Agent No.: IN / PA / 2874 Agent for the Applicant

Claims

Claims, l / We Claim,1. A High-Efficiency Powertrain System for Long-Range Electric Vehicles, adaptable to a wide range of vehicle configurations, including two-wheelers, three-wheelers, four- wheelers, and heavy-duty vehicles comprising: a battery (1) configured to supply electrical power; a transformer (2a) electrically coupled to the battery (1), configured to multiply the voltage supplied by the battery (1) to a predetermined level required by a motor (3); the motor (3) electrically coupled to the transformer (2a), configured to convert the supplied electrical power into mechanical energy; an alternator (4) mechanically coupled to the motor (3), configured to generate electrical energy during the operation of the motor (3) and supply the generated electrical energy back to the battery (1) to maintain its charge; a gearbox (5) mechanically coupled to the alternator (4), and is multi-speed system to provide varying torque and speed to the vehicle's wheels; a Separate Electric Power Terminal (SEPT) (6) configured to direct power from a charging cell to the battery (1) through another identical transformer (2b) for rapid recharging when the battery (1) is in a discharged state; wherein the operation of the said powertrain system, initiates by supplying electrical power from the battery (1) to the transformer (2a); multiplying the voltage of the supplied electrical power using the transformer (2a) to meet the voltage requirements of the motor (3); converting the multiplied electrical power into mechanical energy using the motor (3);Page 17 of 23driving the alternator (4) with the mechanical energy produced by the motor (3); generating electrical energy using the alternator (4) and feeding the generated electrical energy back to the battery (1) to maintain its charge; transferring torque from the motor (3) to the gearbox (5) to drive the vehicle's wheels; and recharging the battery (1) using the SEPT (6) through the transformer (2b) when the battery (1) is in a discharged state, allowing the vehicle to resume operation with minimal downtime.

2. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the motor (3) is selected from the group consisting of an AC / DC brushless motor, dielectric motor, induction motor, permanent magnet motor, permanent magnet synchronous motor, synchronous reluctance motor, and switched reluctance motor.

3. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the battery (1) is selected from the group consisting of Lithium-Ion (Li-Ion), NMC (Nickel Manganese Cobalt), LFP (Lithium Iron Phosphate), NCA (Nickel Cobalt Aluminum), Solid-State, Nickel-Metal Hydride (NiMH), Lithium-Polymer (LiPo), Lithium-Manganese Oxide (LMO), Nickel-Cadmium (NiCd), Sodium-lon, Zinc-Air, Lead- Acid, Advanced Lead-Acid (AGM), Hydrogen Fuel Cells, Vanadium Redox Flow, Redox Flow, Lithium Titanate (LTO), Sodium-Sulfur (NaS), Zinc-Bromine, and Lithium-Sulfur (Li-S).

4. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the alternator (4) is configured to perform dual functions of transferring mechanical rotation to the gearbox (5) and generating electricity to be supplied back to the battery (1).

5. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the gearbox (5) is designed to provide high torque at initial gears for acceleration and high speed at subsequent gears for maintaining top speed.Page 18 of 236. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the SEPT (6) is configured to charge the battery (1) to a specific level based on the charging cell's maximum voltage capacity.

7. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein rapidly recharging the battery (1) using the SEPT (6) when the battery(1) is discharged, ensuring minimal downtime and continued vehicle operation.

8. The High-Efficiency Powertrain System for Long-Range Electric Vehicles as claimed in claim 1, wherein the vehicle is capable of achieving a range of up to 10,000 kilometres on a single charge without the addition of extra batteries.Dated: Wednesday, 18thSeptember, 2024Mr. Amitkumar PatelPatent Agent No.: IN / PA / 2874 Agent for the ApplicantPage 19 of 23

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