Parallel hybrid system with electric motor for vehicle
A parallel hybrid drive system for use with utility vehicles includes a battery-powered drive system and an internal combustion engine. The utility vehicle includes a mounting deck having one or more electric deck motors mounted thereon. Each deck motor receives electrical power from and is controlled by a dedicated deck motor controller. Each deck motor controller is in communication with a vehicle controller or a CAN bus connected to a vehicle integration module. Each deck motor includes a pulley and either a one-way mechanical or electric clutch so the deck motor(s) can be selectively belt-driven by the internal combustion engine. The power and control system of the parallel hybrid drive system is configured to return power to the battery source when the motor(s) are engaged by the internal combustion engine.
1 . A hybrid drive system for a utility vehicle comprising:
an electrical power source;
an electric motor having an output shaft and a connector configured to alternatively receive power from or convey power to the electrical power source;
an electric motor compartment containing the electric motor and comprising:
a motor end cap positioned beneath a pulley relative to a mounting deck to which the motor end cap is mounted;
a motor stator housing positioned beneath the motor end cap and extending through a receiving hole in the mounting deck; and
a clutch bearing comprising:
an inner race that is joined to and rotates with a proximal end of the output shaft; and
an outer race that is joined to and rotates with the pulley; and
an internal combustion engine that connects to and selectively drives rotation of the pulley;
wherein:
the electrical power source provides power to the electric motor sufficient to cause the output shaft and inner race to rotate at a first rotational speed;
the internal combustion engine selectively drives rotation of the pulley and outer race at a second rotational speed; and
when the second rotational speed reaches the first rotational speed, the clutch bearing engages such that the first inner race is driven by the outer race.
2 . The hybrid drive system of claim 1 , further comprising a pulley hub fixedly mounted to the pulley, and wherein the clutch bearing is retained within the pulley hub.
3 . The hybrid drive system of claim 1 wherein, when the clutch bearing is engaged and belt power applied to the pulley exceeds a load applied to the output shaft, the connector conveys power from the electric motor to the electrical power source.
4 . The hybrid drive system of claim 1 , wherein the inner race is connected to the output shaft by a threaded fastener that passes through a central hole in the pulley and into a threaded bore of the output shaft.
5 . The hybrid drive system of claim 1 , wherein the inner race is connected to the output shaft by a threaded fastener, and wherein the pulley covers over and conceals a top of the threaded fastener.
6 . The hybrid drive system of claim 1 , further comprising at least one deck spindle driven by a belt connected to the output shaft of the electric motor such that the at least one deck spindle rotates with the output shaft.
7 . The hybrid drive system of claim 1 , wherein the motor end cap comprises a plurality of threaded mounting holes for receiving fasteners through a plurality of mounting holes positioned around the receiving hole.
8 . The hybrid drive system of claim 1 , wherein the motor end cap comprises an electrical compartment configured to receive the connector.
9 . A hybrid drive system for a utility vehicle comprising:
an electrical power source;
an electric motor having an output shaft and a connector configured to alternatively receive power from or convey power to the electrical power source;
a clutch mechanism having a ratchet that is joined to and rotates with the output shaft at a first rotational speed and at least one pawl that is joined to and rotates with a pulley at a second rotational speed; and
an internal combustion engine that connects to and selectively drives rotation of the pulley;
wherein, when the pulley rotates at a predetermined second rotational speed, the at least one pawl pivots about a pivot pin causing the at least one pawl to contact the ratchet; and
wherein, if the at least one pawl is contacting the ratchet and the second rotational speed matches the first rotational speed, the output shaft is then driven by the internal combustion engine.
10 . The hybrid drive system of claim 1 , wherein the electric motor compartment further comprises a motor output cap through which a distal end of the output shaft extends.
11 . The hybrid drive system of claim 3 , further comprising an electric motor controller that directs the power from the electric motor to the electrical power source when the electric motor controller determines the clutch bearing is engaged and belt power applied to the pulley exceeds the load applied to the output shaft.
12 . The hybrid drive system of claim 9 wherein, when the output shaft is driven by the internal combustion engine, the connector conveys power to the electrical power source.
13 . The hybrid drive system of claim 9 wherein, when the at least one pawl contacts the ratchet, the clutch mechanism is in an engaged state such that the first rotational speed equals the second rotational speed.
14 . The hybrid drive system of claim 9 , further comprising at least one spring configured to bias the at least one pawl toward a disengaged position at which the at least one pawl does not contact the ratchet.
15 . A hybrid drive system for a utility vehicle comprising:
an electrical power source;
an electric motor comprising an output shaft;
a connector configured to alternatively convey power to the electric motor from the electric power source or convey power from the electric motor to the electrical power source;
a housing containing the electric motor, the housing positioned below a pulley and mounted to a mounting deck having a receiving hole through which the output shaft extends, the housing comprising:
a motor end cap mounted to the mounting deck; and
a motor stator housing that extends through the receiving hole;
a clutch bearing comprising:
an inner race that is joined to and rotates with the output shaft; and
an outer race that is joined to and rotates with the pulley; and
an internal combustion engine that connects to the pulley via a belt.
16 . The hybrid drive system of claim 15 , wherein, when the inner race and the outer race rotate at the same speed, the connector conveys power from the electric motor to the electric power source.