Adapter System for Repowering Electric PTVs with Internal Combustion Engines
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Solution Overview
Problem
Existing methods for repowering electric motor-powered personal transport vehicles with internal combustion engines are impractical due to incompatibility between powertrains, lack of reversing mechanisms, and challenges in mounting accessory components like oil cooling and exhaust systems.
Innovation Solution
A system and method that includes a power unit with an internal combustion engine, integrated continuously variable transmission (CVT), and forward/reverse gearbox, along with an adapter system to connect the power unit to the transaxle, allowing for the conversion of electric motor-powered vehicles to engine-powered vehicles by reorienting the transaxle and installing necessary components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electric motor-powered PTV is repowered with an internal combustion engine, then the vehicle can operate without battery replacement and gain greater power output, but the powertrains are incompatible due to lack of reversing mechanism and mounting challenges
Solution Approach 1:
An adapter system is introduced as an intermediary component between the existing electric motor powertrain and the new internal combustion engine. The adapter includes a mounting plate with engine mounting pads, a transaxle adapter with input shaft, and a output shaft adapter, which mediate the mechanical connection and enable compatibility between incompatible powertrains without requiring complete redesign of the vehicle's power delivery system
Solution Approach 2:
The adapter system is divided into multiple separable components: a mounting plate for engine attachment, a transaxle adapter with input shaft, and a output shaft adapter. This segmentation allows each component to be optimized independently and facilitates easier installation and removal of the internal combustion engine while preserving the original electric motor powertrain components
2Device complexity
If a simple direct-drive transaxle from an electric motor-powered PTV is used, then the transmission is simpler, but there is no forward/reverse gearbox mechanism for internal combustion engine operation
Solution Approach 1:
The adapter system merges the simple direct-drive transaxle design with forward/reverse gearbox functionality by integrating a gear mechanism within the transaxle adapter assembly. The input shaft adapter includes gear teeth that engage with the engine's output shaft, providing both direct drive and reversed rotation capabilities, thus combining simplicity with the required directional control for internal combustion engine operation
3Reliability
If engine accessory components like oil cooling system and exhaust system are installed, then the internal combustion engine can operate properly, but mounting challenges arise due to the vehicle's original electric motor design
Solution Approach 1:
The mounting plate is designed with universal adaptability, featuring multiple engine mounting pads and attachment points that can accommodate various engine configurations and accessory component orientations. The plate serves multiple functions: securing the engine, providing mounting surfaces for accessory components, and routing pathways for exhaust and cooling systems, thereby simplifying the installation of engine accessories without requiring vehicle-specific custom fabrication
Data Source
AI summary
A system and method are provided for repowering an electric motor-powered PTV to convert it into an engine-powered PTV. The system includes a power unit with an ICE, an integrated CVT, and an integrated forward/reverse gearbox. An adapter system includes an adapter geartrain that includes a transmission intermediate gear that is configured to overdrive a transmission output shaft. The transmission output shaft may be internally splined.