Wheel-Coupled Generator Layout for Extending EV Range

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Solution Overview

Problem

The limited range and lengthy charging time of electric vehicles due to battery capacity and charging infrastructure limitations hinder their widespread adoption.

Innovation Solution

A vehicle system that converts kinetic energy into electrical energy using a generator coupled to the wheels, which is then stored in the battery, thereby extending the vehicle's range without increasing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If the battery capacity is increased to extend the vehicle range, then the range is improved, but the vehicle weight and cost increase

Engineering Contradiction:
Improvevehicle rangeVSAvoidbattery weight
Core Design Contradiction:
Duration of action of moving objectVSWeight of moving object

Solution Approach 1:

The invention converts the harmful effect of braking (kinetic energy dissipation) into a beneficial effect by using the generator to convert kinetic energy into electrical energy during deceleration, which is then stored in the battery. This regenerative braking system extends the vehicle range without requiring a larger battery, thus avoiding the weight penalty associated with increased battery capacity.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

2Duration of action of moving object

If the battery capacity is increased to extend the vehicle range, then the range is improved, but the vehicle cost increases

Engineering Contradiction:
Improvevehicle rangeVSAvoidvehicle cost
Core Design Contradiction:
Duration of action of moving objectVSEase of manufacture

Solution Approach 1:

The regenerative braking system recovers kinetic energy that would otherwise be wasted during deceleration, converting it into electrical energy stored in the battery. This reduces the total energy demand from the battery, allowing for a smaller, less expensive battery while achieving the desired range extension.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system enables the vehicle to recharge itself during operation through regenerative braking, reducing reliance on external charging infrastructure and decreasing the required battery capacity for a given range, thereby lowering overall vehicle cost.

Inventive Principle:
Principle #25Self-service

3Duration of action of moving object

If regenerative braking is implemented, then the vehicle range is extended, but the device complexity increases

Engineering Contradiction:
Improvevehicle rangeVSAvoidsystem complexity
Core Design Contradiction:
Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The generator serves multiple functions: it acts as a motor during vehicle acceleration and as a generator during regenerative braking. This multi-functionality reduces the need for separate components and simplifies the overall system architecture, offsetting the complexity introduced by the regenerative braking capability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the motor and generator functions into a single electric machine, eliminating the need for separate motor and generator components. This integration reduces system complexity while maintaining the ability to provide both propulsion and regenerative braking functions.

Inventive Principle:
Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Significantly increases the range of electric vehicles by utilizing recovered kinetic energy, reducing reliance on battery capacity and charging time.

Implementation Method 1

The electric generator (12) is permanently installed in the vehicle (1) in the area of a rear wheel (3). The generator (12) is coupled to one of the rear wheels (3) via a transmission device in the form of a belt drive (13). When the rear wheel (3) rotates, for example while driving, the electric generator (12) is also set in rotation via the second pulley (16), the drive belt (17) and the first pulley (15), which in the process generates a three-phase alternating current.

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP4578704A1Range-optimized electrically driven vehicle
Publication Date: 2025.07.02 ISSA ORANS
  • EP4578704A1 patent drawingFigure 1
  • EP4578704A1 patent drawingFigure 2~3
  • EP4578704A1 patent drawing

AI summary

The invention relates to a vehicle (1) with at least two wheels (2, 3) for rolling on a surface, which vehicle has an electric drive unit for driving at least one of the wheels (2). The electric drive unit has at least one electric motor (4) which is connected in a rotationally fixed manner to the at least one wheel (2) via drive means (25), and an electric accumulator (5) which is electrically connected to the electric motor (4). To generate a driving movement, the electric motor (4) can be supplied with electrical energy from the accumulator (5). In order to increase the range of such a vehicle (1), the invention proposes that the vehicle (1) have an electric generator (12) and a transmission device (13, 27, 32, 35), and that the generator (12) is coupled to a wheel (3) by means of the transmission device (13, 27, 32, 35) to transmit the rotation of the wheels (2, 3) of the vehicle (1) to the generator (12).The generator (12) is also electrically connected to the accumulator (5) in order to feed the electrical energy generated in the generator (12) into the accumulator (5).