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United States Patent
Caliskan et al.
ELECTRIFIED VEHICLES WITH
REMOVABLE AND INTERCHANGEABLE,
RANGE EXTENDING GENERATORS,
(C, Dearborn, MI(US)
Inventors: Avi Caliskan, Canton, Mi (US); John
Jaranson, Dearborn, MI (US): Peter A.
Friedman, Ann Arbor. MI (US)
Arnold Kadiu, Dearborn, MI (US)
Assignee: FORD GLOBAL TECHNOLO
(C, Dearborn, MI(US)
Notice: Subject to any disclaimer, the teem ofthis
pateat is extended of adjusted under 35
USC. 154(b) by 8 days.
Appl. Now 18/963,202
Filed: Apr 26, 2018
‘ioe Publication Data
$ 201910329687 AL Oct. 31, 2019
Im. Cl,
BoOK 800 (2006.01)
BOOL S3/18 (2019.01)
B60 S061 (201901)
u
fad BOOL. $314 (2019.02); BOOK 8/00
(QO13.01): AOL S061 (2019.02), BOOL
2200036 2013.01)
Field of Clasitcat
cre B6OL. 11/1809)
‘See application file for compte search history.
Search
US010773602B2
US 10,773,602 B2
ep. 15, 2020
(10) Patent No.:
(4s) Date of Patent:
66) References Cited
US. PATENT DOCUMENTS.
571.949 B2 62003 Bums IV eal
Gs9o041 27003 Toll
1065.31
7514803 B2* 42009 Wilks BeOL 111822
1168
SS98KST BL* 72016 Theobald Book 1600
Sustisas B2* 102016 Caldeies Beal 30046
aoopotesios AL 102002 Brot BOK 9 106
20060000650 A1* 1/2006 Hughey B6OK 6/36
180065.25
1s065.21
20110225539 A1* 92011 Hass GOK 646
(Continved)
POREIGN PATENT DOCUMENTS
De
Primary Examiner’
Assistant Examiner
(4) Attornes, Agent or Firm
Carlson, Gaskey & Olds
on ABSTRACT
Tie disclosure details electrified vehicles that are equipped
with removable generators for inereasing the electric rmige
of the vehicles. An exemplary electrified vehicle includes
fargo space, sich asa tack bad, and generator removably
positioned within the eargo space, The generator is adapted
fo selectively supply power for ether charging battery
peek ofthe eletrifed vehicle or for propelling one or more
Vehicle drive wheels. Ia some embodiments the generator is
shaped lke, and therefore disguised as, a toolbox
16 Claims, 5 Drawing Sheets
10-2015-005318 AL 102016
James A Shriver I
James J Trigas
David B. Kelley
—[ inecer }
aching
Electie
257
Graing
wUS 10,773,602 B2
Page 2
66) References Cited
USS. PATENT DOCUMENTS.
20150015065 AL* 1/2015 Bruns B01. 300
307108
2O1S210182 AL* 7/2015. Adkus B60 11 1809|
1806s 248
20160000232 AL 2016. Baday
* cited by examinerUS 10,773,602 B2
Sheet 1 of §
Sep. 15, 2020
U.S. Patent
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1
ELECTRIFIED VEHICLES WITH
REMOVABLE AND INTERCHANGEABLE,
RANGE EXTENDING GENERATORS,
‘TECHNICAL FIELD
‘This disclosure dotils elected vehicles that are
‘equipped with removable generators for inereasing the elee>
tric range of the vehicles
BACKGROUND
The desire to reduce automotive fel consumption and
‘emissions has boen well dacuented, Therefore clostified
Ychicles are being developed that reduce or completely
‘eliminate reliance on internal combustion engines. In gen
feral, eloctified vehicles differ from conventional motor
‘Vehicles because they are selectively driven by one or more
battery powered electric machines. Conventional motor
vehicles, by contrast, rely exclusively on the intemal com
bution engine to propel the vehicle.
‘A igh voltage battery pack typically powers the electric
machines and other electrical loads of the electrified vehicle
‘The high voltage batery pack provides a limited amount of
clectric-only driving singe. Some customers desire the abil-
jty to add addidonal electric-only range to their elected
vehicles.
SUMMARY,
Anelectrifed vehicle according to an exemplary aspect of
the present disclosure includes, among other things, a drive
wheel, battery pack, a cargo space, and) a generator
Femovahly positioned within the cargo space and adapted to
selectively output power for ether changing the battery pack
‘or propelling the drive wheel, The generator is shaped like
‘toolbox,
TIn-a farther non-limiting embodiment of the foregoing
‘lecitiod vehicle, the electrified vehicle is 9 pickup tuck,
Ina further nonlimited embodiment of either of the
‘foregoing eletifed vehicles, the cargo space is established
by a truck bed of the pickup track,
In a further non-limited embodiment of any of the Fore=
oing electrified vehicles, at least a portion ofa bottom wall
Of the generator is spaced a distance above a floor of the
‘cargo spc.
Tn Turthee non-limited embodiment of any of the Fore=
poing electrified vehicles, the generator includes an enclo-
sure that Houses an engine and a fuel tank
Tn a further non-limted embodiment of any of the Fore=
poing elected vehicles, the enclosure futher houses an
‘exhaust system and electronics of the generator.
In a further non-limited embodiment of any of the Fore
poing electrified vehicles, the vehicle includes a connection
system for electrically connecting the generator toa voltage
bus of the eleczfied vehicle
Tn a further non-limitad embodiment of any of the fore=
oing electrified Vehicles, the consoction system includes @
Vehicle-side connector and a generaor-side connector.
Ina further non-limited embodiment of aay of the Fore=
oing electrified vehicles, the vehicle-side connector is
recessed into a Moor of the cargo space and the generator
side connector protrades from a bottom wall ofthe genera-
‘In a further non-limitad embodiment of any of the fore
ping electrified vehicles, the vehicle-side connector is a
{emale connector and the battery-side connector is @ male
‘connector.
0
o
2
4 further noa-limited embodiment of any of the fore=
soing electrified vehicles, the generator includes locating
stud received within openings ofthe eargo space
In a further noa-limited embodiment of any of the Fore:
soing electrified vehicles, the generator is interchangeable
with a second generator that includes a different poser
capacity compared to the generator.
Ina further noo-limited embodiment of any of the Fore-
going electrified vehicles, the generator is connected in
series relative to the battery pack.
Ina further noa-limited embodiment of any of the Fore:
going electrified vehicles, a contol system is configured 10
‘canto the power outputted by cach of the batery pack and
the generator during @ drive eyee.
‘In a further non-limited embodiment of any of the fore
ing electrified vehicles, human mochine interface is in
‘communication with the control system and configured 10
receive an operating mode input for controlling the gener
tor during the drive eyele
A method acconting (0 another exemplary aspect of the
present disclose includes, among other things, positioning
4 gencrator within a cango space of an electrified vehicle,
‘The generator is disguised as @ toolbox. Power from the
sdenertor may be output for either propelling a whee! ofthe
lecirifed vehicle or charging a batery puck of the elets-
fied vehicle,
Tn a further non-limiting embodiment of the foregoing
‘method te method includes outputing the power from the
szencmitor and power from the batery pack ia parallel
In a further nou-limiting embodiment of either of the
{foregoing methods, outputting the power from the generator
is only performed when a state of charge ofthe battery pack
falls below a threshold level,
In a further non-limiting embodiment of any of the
foregoing methods, positioning the generator within the
cargo space includes Connecting a vehiele-sde connector to
a generator-sde connector.
Tn a farther non-limiting embodiment of any of the
foregoing methods, the method includes removing the gen-
erator from the eargo space and replacing the generator with
‘a second generator that has a dilferent power capacity than
the generator
‘The embodiments, examples and alternatives of the pre=
ceding paragraphs, the claims, or the following description
‘and drawings, including. any of their various aspects or
respective individual feaues, may be taken independenty
fr in any combination, Features deseribed in connection
with one embodiment are applicable to all embodiments,
unless such features are incompsle
"The various features and advantages of this disclosure
will become apparent to those skilled inthe art from the
following detailed description. The drawings that accom
ppany the detailed description can be brielly described as
{allows
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates 4 powertrain of an elee-
trifle vehicle
FIG. 2 illustrates an electfied vehiele that may employ
the powertrain of FIG. 1
FIG. 3 schematically illustrates the nterchangeability of
diffrent sized generators that may be emplayed by the
electrified vehicle of FIG. 2
FIG. ilstmtes a generator of the electrified vehicle of
FIG. 2,US 10,773,602 B2
3
FIG. 5 illustrates a connection system for connecting a
enerator 1 a voltage bus of an electrified vehicle
FIG. 6 illustrates a generatorsde connector of the con-
nection system of FIG. 5.
FIG, 7 illustrates a vebicle-side conaector of the connec:
tion system of FIG. 5.
IG, 8 ilustates an eletric drive system aovording 0 a
first embodiment ofthis disclosure.
PIG, 9ilusintes an electric drive system aocording io &
second embodiment ofthis disclosure
DETAILED DESCRIPTION
‘This disclosure dotils clectified vehicles that are
‘equipped with removable generators fr increasing the elec
tric range of the vehicles. An exemplary electrified vehicle
includes a cargo space, sch as a trck bed, andl a generator
removably positioned within the cargo space. The generator
is adapted to selectively supply power for ether charging &
buttery pack of the electrified vehile or for propelling one
‘or more vehicle drive wheels. In some embodiments, the
enerator is shaped like, and therefore disguised as, a
toolbox. These and other features are discussed in grester
detail inthe following paragraphs of this detailed descrip
FIG. 1 schematically Ulustrtes a powertrain 10 of a
‘electrified vehiele 12. In an embodiment, the electrified
vehicle 12 is batery electric vehicle (BEV) that is pro-
pelle solely through electric power, such as by an electric
machine M4, without any assistance from an intemal com
bastion engine. The electric machine 1d roceives electrical
power and provides a rotational output poser. [aan embodi-
ment, the electric machine 14 isan elecirie motor.
The electric machine 14 may be connected to a pearbox.
16 for adjusting the output torgue and speed ofthe electric
machine 14 by a predetermined gear ratio, The gearbox 16
js connected ta set of drive wheels 18 by an output shaft
20. A voliage bus 22 eloctically’ connects the electric
Iachine 14 to a battery pack 24 thromgh an inverter 26, The
‘eleciic machine 1, the gearbox 16, and the inverter 26 may
be collectively refered to asa transmission 28
The battery pack 24 is an exemplary electrified vehicle
butiery. The battery pack 24 may be a high voliage traction
battery pack that includes @ plurality of battery arrays 28
(Ge, hattery assemblies or groupings of battery eels)
‘capable of outputting electrical power to operate the electric
machine 14 andor other eletrcal loads of the electrified
vehicle 12 for providing the power necessary to propel the
wheels 18. Other types of enemy storage devices andor
‘output devices ean also be used to electrically power the
‘lecrfied vehicle 12
The electrified vehicle 12 is also be equipped with a
‘charging system 30 for charging the energy storage devices
(eae, battery cells) of the battery pack 24. The charging
system 30 ean be connected to an extemal power source for
receiving nd distributing power received from the extemal
power source to the batery pack 24
The electrified vehicle 12 may be operable to travel over
4 specific distance prior (o energy depletion of the battery
pack 24, which may lead to operator range anxiety. Avcord-
ingly, the electrified vehicle 12 may additionally be
‘equipped witha generator 84 for inereasing the travel range
‘of the eloctifed vehicle 12, Like the battery pack 24, the
‘generator §4 may be operably connected to the electric
machine 14 through the inverter 26 over the vollage bus 22.
‘The generator $4 may also be connected either in parallel oF
Jn series relative to the battery pack 24. As discussed i
0
o
4
areater detail below, the generator $4 may be a gasoline
driven generator tht is removable and interchangeable
‘The powertrain 10 shows in FG. 1 is highly schematic
and is not intended to limit this disclosure. Various addi-
tional components could altematively or additionally be
employed hy the powertmin 10 within the scope of this
iselosure. In adltion, the teachings ofthis disclosure may
be incorporated into any type of electrified vehicle, inciud-
‘ng but not limited to trucks, sport lity vehicles, ears, ee
FIG, 2 illustrates an electeified vehicle 12 that may
employ the powertrain 10 shown in FIG, 1, oF any other
clectrified poweririn. In an embodiment, the elevfied
vehicle 12 i «pickup track. Although a specific component
relationship is lustrited in the figures ofthis diselostre, the
illstations are not intended to limit this disclosure. The
placement and orientation ofthe various components of the
lectrified vehicle 12 are shown schematically and could
vary within the seope of this disclosure, In addition, the
various figures aecompanying this disclosure are not ncees-
sarily to scale, and some features may be exaggerated oF
‘minimized to show certain details o a parila component.
“The clectified vehicle 12 includes a trick bed 56 that
establishes a cargo space for storing and hauling eargo at a
reat location of the electrified vehicle 12. The truck bed 56
is wenerally rearward of a passenger eabin 58 of the elee-
trifle vehicle 12 and includes a floor 60 extending between
pair of longitudinally extending side walls 62, a laterally
extending front wall 64, and tailgate 66. The tailgate 66 is
moveable between a closed position (not shown) and
deployed or open position. When in th closed position, the
tailgate 66 generally encloses an end ofthe ruck bed $6 that
js opposite from the front wall 64 to prevent cargo from
sliding out of the teuck bed 56, When ia the open position,
the tailgate 66 is generally horizontal and Unts parallel to
saround level suc that cargo ean be loaded onto or unloaded
from the trick bed 6
‘The generator $4 may be positioned within the trek bed
56, such a near the front wall 64. In an embodiment, the
generator $4 i shaped Tike, and therefore disguised as, a
toolbox. Disguising the generator $4 as a toolbox gives the
ceustomer the option to add addtional electric range to the
clecirfied vehicle 12 without sacrificing any more cargo
space than would be taken up by a traditional saddle style
‘tuck bed toolbox. In te installed position, at least a portion
‘of a bottom wall 84 of the generator $4 may be spaced a
‘stance D above the Moor 60 of the truck bed $6. Therefore,
cargo may be slid underneath the generator $4 even when
the electrified vehicle 12 is equipped wih the generator 84
Referring to FIGS. 2-3, the generator 54 may be remov-
able from the truck bed $6 and interchanged with different
sized generators fo accommodate the specific enerzy needs
of the eustomerluser. In such @ modular design, the eu
tomeriuser could employ a small (eg. $ kW with 5 gallon
capacity), medium (eg, $ kW with 10 gallon capacity), oF
large (¢., 15 kW with 20 gallon capacity) generator §4
‘within the tuck bed $6, The small generator $4 may occupy
8 fist amount of space SI of the truck bed 56, the medi
snenerator $4 may occupy a second amount of space S2 ofthe
{ruck bed $6, and the lage generator 54 may occupy a third
amount of space $3 of the tuck bed $6, The second amount
fof space SP is greater than the first amount of space SI, and
the third amount of space 83 is greater than the second
amount of space $2. Incrsasing the travel range of the
electrified vehicle 12, such as by using a laner-sized en-
femtor $4, may therefore reduce the amount of available
cargo space within the eletrifed vehiele 12,US 10,773,602 B2
5
FIG, 4 illustrates additional feanures of the exemplary
enerator $4 of FIG. 2. FIG. isa top, eross-sectional view
‘of the generator 4 fr visualizing is internal contents. Tn aa
‘embodiment, the generator 84 inehides an enelostre 68 that
houses an engine 70 or other power souree, a fe tank 72,
fan exhaust system 74, and various electronics 76. Other
‘components could adkltionally be housed inside the enclo~
sre 68 within the scape of this disclosure.
The enclosure 68 may be shaped like a toolbox in onder
to disguise the generator 4 as a truck bed toolbox. The
‘enclosure 68 may be constructed of polymer-based mate
Fial, « metallic material, or a combination of polymer-based
‘and metallic materials, Hossever, the actual size, shape, and
material make-up of the enclosure 68 are not intended t0
limit this disclosure,
The engine 70 is the main power source of the generator
54. During operation, the engine 70 creates mechanical
‘energy that is converted into electical energy that can be
‘outputted by the generator 84. The operating specifications
‘of the engine 70 are design specific and can be selected 10
provide @ desired electrical energy out
‘The fuel tank 72 stores fel for powering the engine 70
JInan embodiment, the fue s gasoline. However, other fuels
‘are also contemplated within the seope of this disclosure,
‘including but not limited to, diesel, propane, natural g35, oF
‘any combination ofthese or other fuels.
‘he exliaust system 74 is adapted to remove excess heat
‘and exhaust gases fom the generator 84, sue as those that
may be generated by the engine 70, The exhatist system 74
may include fans, vents, pumps, heat exchangers, ete
“The electronics 76 generally contol the operation of the
various components ofthe generator $4. In an embodiment
the electronics 76 inchide the necessary hardware and sole
are for controlling the components ofthe generator $4 and
{or achieving bi-lrectional communication with the com
onents of the powertrain 10 of the electrified vehicle 12.
‘The elecironies 76 may inckude various contol units, vol
age regulators, switches, ot
“The generator 84 could optionally include one or more
power outlets 32. The power outlets 32 may be avcessible
fom an exterior ofthe enclosure 68. The owneritser af the
‘locfied vehicle 12 may plug. any tools or other electrical
socessories into the power outlets 32 in order to power these
tools using energy provided by the generator $4, Thus, ia
‘addition to providing power to the powertrain 10, the
generator $4 could adkltionally power various accessory
vices,
FIG. 5, wth continued reforence to FIGS. 1, 2,3, and 4,
‘ustates a connection system 78 for electrically connecting
the generator $4 to the voltage bus 22 of the electrified
vehicle 12. The connection system 78 may include a vehicle-
side connector 80 and a generatorside connector 82. In an
‘embodiment, Uke vehicleside connector 80 is rigidly dis
posed within the floor 60 of the truck bed $6, and the
enerator-sde connector 82 is rigidly disposed in bottom
‘wall 84 of the enclosure 68 ofthe generator 84. In another
‘embodiment, the vehicle-side connector 80 is a female
‘connector and the generator-side connector 82 is @ male
‘connector, However, aa allemative contiguration is also
‘contemplated in which the vehicleside eonnector 80 i the
male connector and the generatorside connector 82 is the
female connector. The generatr-side connector 82 may be
phgget into the vehice-side connector 80 to connect the
‘Benerator S440 the voltage bus 22
‘The connection system 78 may additionally include one
‘or more locating features for aligning the gencrator-side
‘connector 82 with the vehicleside connector 80 a the
0
o
6
szenerator $4 is moved into positon within the truck bed $6
In an embodiment, the enclosure 68 of the generator §4
includes locating. studs 86 that protude inwardly Irom
‘mounting Ranges 88 located at each opposing side of the
enclosure 68, The locating studs 86 may be received within
‘openings 90 formed in the side walls 62 ofthe track bed 56
The locating studs 86 may be slid into the openings 90 to
align the generatorside connector 82 with the vehicleside
connector 80. Therefore, as the generator 4 is. moved
‘urther toward the loor 60 during installation, the penerator-
side connector 82 will be properly positioned for engaging
the vehicle side connector 80.
FIG, 6 illustrates the generatorside connector 82 of the
connection system 78, The generator-side connector 82 may
slightly protrude outwardly from the bottom wall 84 of the
enclosure 68. The generatorside connector 82 may include
Jow voltage connection ports 92 and high voliage connection
ports 94. Of course, the generator-side connector 82 could
embody other configurations within the scope of this dis-
closure,
“The high voltage connection ports 94 allow the generator
4 10 be connected with the battery pack 24 andlor the
inverter 26. The low voltage ennncction ports 92 allow for
CAN communication between the generator S4 and the
battery pack 24, the inverter 26, or other components ofthe
powertrain 10.
‘he generator-sde connector 82 may additionally include
4 Tock setuator 96, The lock actuator 96 is configured +o
prevent removal ofthe gencrator-side connector 82 from the
‘ehicle-side connector 80 while the electrified vehicle 12 is
‘operating (Le. ignition is tumed ON),
PIG, 7 illustrates the Vehicle-side connector 80 of the
connection system 78, The vehicle-sde canncetor 80 may be
slightly recessed into the foor 60 ofthe truck bed $6. The
connection ports of the vehicle-side connector 80 may
generally mirror those of the generctorside connector 82
and may include low voliage connection ports 98, high
voltage connection ports 100, and a Toek actuator 102, The
battery-rce connector #2 could embody other configure
‘ions within the scope of this disclosure,
"The battery pack 24 andthe generator $4 ofthe clctified
vehicle 12 may be controlled to simultaneously utp
power for powering the cletric machine 14 of the electrified
Vehicle 12. The elecsic machine 14 may then output torque
Tor propelling the one or more drive wheels 18 of the
lectifed vehicle 12
‘As showin in PIG. 8, the battery pack 24 and the generator
‘34 can be controled bya contol system 99 to provide power
to the electric machine 14 in parallel with one another. The
‘control system 99 may inelude hardware, software, or both,
{orperfonming the necessary contro factions for outputting
power from the battery pack 24 and the generator $4
Althougls shown as a single hardware device, the contol
system 99 could inclade multiple controllers in the form of
multiple hardware devices, or multiple software controllers
within one or more hardware devices. In addition, the
control system 99 may include one or more processing units
and non-iransitory memory for executing te various contol
Sategies and modes ofthe electrified vehicle 12
‘The control system 99 may be programmed to control the
‘amount of power outputted by each of the battery pack 24
fand the generator $4 during each operating mode of the
‘lectifed vehicle 12, Inan embodiment, the contol system
9 automatically commands the generator $4 "ON? if a
power demand of the electrified vehicle 12 exceeds a
predefined power threshold. In ancther embodiment, the
‘control system 99 automatically commands the generator $4US 10,773,602 B2
1
“ON'ifthe state of charge (SOC) ofthe battery pack 26 falls
below a predefined threshold
In yet another embodiment, the contol system 99 is
programmed to contol the power outputted by each of the
battery pack 24 and the generator $4 during a given drive
‘eyele based on inputs from the eustomerivser. Par example,
the clectified vehicle 12 may inclode a human machine
interface (HMI) 104 that is in electrical communication with
the conto! system 99. The HMI system 104 may be located
within the passenger cabin 58 of the cletrfied vehicle 12
and may include one of more user interfaces 106. The
‘customev/user may interoet with each user interface 106 via
‘ touch sereen, tate butions audible speech, speech syn=
thesis, ete. The customeriuser can either enter information
Jno the user interface 106, oF the user interface 106 can