DESC:ELECTRIC VEHICLE COMPRISING POWERTRAIN ASSEMBLY DISPOSED WITHIN OPEN CRADLE
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202221075288 filed on 25/12/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to an electric vehicle. Particularly, the present disclosure relates to an electric vehicle comprising a powertrain assembly disposed within an open cradle.
BACKGROUND
Electric vehicles (EVs) are increasing in popularity in the automotive market due to their cost-effectiveness and environmental friendliness. EVs are particularly efficient for short-distance travel compared to traditional modes like buses and metro trains. Further, an important part of an EV is the electric motor that is powered by a battery pack and a gearbox that drives the EV.
However, such components are heavy and large and therefore, posing challenges in terms of vehicle design and space utilization. In conventional EVs, components such as the motor and gearbox are mounted deep within the frame of the EV, thereby, requiring a robust frame with high load-carrying capacity. It will be appreciated that such mounting of the motor and gearbox increases the cost of the vehicle, such as, for disposing electrical connections, mechanical support structures and/or electromechanical components (such as cooling systems) throughout the frame. Consequently, the available space for arranging other components of the vehicle is severely limited, increasing the weight associated with the EV and decreasing an operating range of the EV.
Thus, there exists a need for an electric vehicle that overcomes the one or more problems associated with mounting of powertrain components such as the motor and gearbox within electric vehicles as set forth above.
SUMMARY
An object of the present invention is to maximize the available space within the vehicle chassis, allowing for more efficient use of space and the possibility of including additional or larger components.
In accordance with a first aspect of the present disclosure, there is provided an electric vehicle (EV) comprising a chassis comprising a closed cradle and an open cradle. A battery-pack compartment is disposed within the closed cradle and a powertrain assembly is disposed within the open cradle through at least one mounting point. The powertrain assembly is arranged underneath the battery-pack compartment.
The present disclosure provides an electric vehicle comprising a powertrain assembly disposed within an open cradle. Advantageously, the electric vehicle enables efficient utilization of the space within the chassis by housing the battery-pack compartment within the closed cradle, thereby maximizing the available space and allowing for a more compact and efficient design. Furthermore, the positioning of the powertrain assembly underneath the battery-pack compartment in the open cradle contributes to better weight distribution within the vehicle, thus lowering the centre of gravity and improving vehicle handling and stability. Advantageously, the arrangement of the powertrain assembly within the open cradle with at least one mounting point makes the powertrain assembly more accessible for maintenance and repairs, thereby simplifying the process of servicing the vehicle and reducing maintenance costs and downtime. Furthermore, the positioning of the powertrain assembly allows for better airflow and efficient cooling, which is crucial for maintaining optimal performance of the powertrain components and prolonging their lifespan.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a bottom-perspective view of a partial chassis of an electric vehicle (EV), in accordance with an embodiment of the present disclosure; and
FIG. 2 illustrates a top-perspective view of the chassis of FIG. 1 with the battery-pack compartment and the powertrain assembly removed.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a motor of an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms ‘electric vehicle’, ‘EV’, and ‘EVs’ are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries (interchangeably referred to as a ‘battery pack’ or ‘battery packs’) which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheelers, electric three-wheelers, electric four-wheelers, electric multi-wheelers (such as electric trucks) and the like.
As used herein, the term ‘chassis’ refers to the fundamental structural framework of a vehicle, designed to support the various components and systems integral to the operation of the vehicle. The chassis includes the base frame, which provides the necessary structural integrity and stability, along with specific supporting structures and members that house or connect critical elements such as the powertrain, battery pack, and suspension systems. The chassis is engineered to balance strength, durability, and flexibility, accommodating various components in a manner that optimizes the overall performance, safety, and efficiency of the vehicle. The chassis serves as the foundation upon which the vehicle is built, influencing handling characteristics, weight distribution, and general design parameters of the vehicle.
As used herein, the term ‘closed cradle’ refers to a specific section or component of the chassis that is designed to be partially or fully enclosed or encapsulated. Such a structural feature of the chassis is characterized by an ability to completely surround and protect certain vital components of the vehicle, such as the battery pack or sensitive electronic systems. The closed cradle is distinguished by robust and secure design, which shields the enclosed components from external environmental factors, impacts, and potential damage. The closed cradle plays an important role in enhancing the safety and longevity of the components housed therein, while also contributing to the overall structural integrity and stability of the vehicle. The closed cradle is typically designed with considerations for accessibility, maintenance, and thermal management, ensuring that the closed cradle not only protects but also supports the optimal functioning of the components housed therein.
As used herein, the term ‘open cradle’ refers to a particular section or component within the chassis that is characterized by an open or accessible area/design. Further, unlike the closed cradle, the open cradle does not fully enclose the components supported by the open cradle but instead provides a framework that allows for easy access to such components, which may include parts of the powertrain assembly or other mechanical systems. The open cradle is designed to facilitate installation, maintenance, and repair of the components housed therein, providing a balance of support and accessibility. Additionally, the open nature of the open cradle aids in efficient cooling of these components by allowing air to circulate around the components. The open cradle is integral to the overall layout of the chassis, contributing to the weight distribution, structural integrity, and functionality of the vehicle, while also ensuring that crucial components are easily reachable and well-ventilated.
As used herein, the term ‘battery-pack compartment’ refers to a designated area or enclosure within the chassis that is specifically designed to house the battery pack. The battery-pack compartment is tailored to securely accommodate the battery pack, which is a crucial component in electric vehicles for storing electrical energy. The battery-pack compartment is engineered to provide not only physical support and protection for the battery pack but also to ensure optimal functioning of the battery pack, such as, by providing for thermal management, protecting the battery pack from extreme temperatures, and ensuring safe operation thereof. Additionally, the design of the battery-pack compartment takes into account factors such as ease of access for maintenance, protection from external impacts or environmental conditions, and efficient integration within the overall design of the vehicle to maintain balance and weight distribution. The battery-pack compartment is a key element in electric vehicle design, directly influencing the range, performance, and safety of the vehicle.
As used herein, the term ‘battery pack’ refers to an assembly of individual battery cells or modules that are interconnected to store and provide electrical energy for operation of the electric vehicle. The battery pack is an important component that powers the electric motor and other electrical systems within the vehicle. The battery pack is typically composed of lithium-ion cells or other advanced battery technologies and is configured to deliver the required voltage, capacity, and power output. The design of a battery pack includes considerations for energy density, efficiency, safety, and longevity. The battery pack often incorporates integrated systems for thermal management, monitoring, and control to maintain optimal performance and to ensure the safety of the battery cells. The battery pack is a fundamental element in determining the range, performance, and overall efficiency of electric vehicles and the design and integration of the battery pack are key to the advancement of EV technology.
As used herein, the term ‘powertrain assembly’ refers to the collective set of components in a vehicle that are responsible for generating and transmitting power to the wheels, enabling the vehicle to move. The powertrain assembly of electric vehicles (EVs) typically includes the electric motor(s), gearbox, drive shafts, and associated control systems. The electric motor converts electrical energy from the battery pack into mechanical energy, while the gearbox adjusts the torque and speed delivered to the wheels. The powertrain assembly is crucial for determining the performance characteristics of the vehicle, such as acceleration, top speed, and efficiency. Additionally, the powertrain assembly often integrates systems for managing power delivery and ensuring smooth operation of the vehicle. The design and configuration of the powertrain assembly play an important role in the overall efficiency, driving dynamics, and sustainability of electric vehicles.
As used herein, the term ‘mounting point’ refers to a specific location or fixture on the chassis that is designated for securely attaching or supporting components or assemblies. The mounting point is typically used for installing parts of the powertrain assembly, such as the electric motor or gearbox, or other critical components such as the battery-pack compartment. The mounting points are strategically designed and positioned to ensure optimal distribution of weight, balance, and stability of the vehicle. Further, the mounting points are engineered to provide robust and stable connections that are capable of withstanding the stresses and vibrations encountered during vehicle operation. The mounting points may also include features for vibration dampening and ease of installation or removal. The configuration and strength of the mounting points are crucial for the safe and efficient functioning of the vehicle, influencing both performance and longevity of the vehicle.
Figure 1, in accordance with an embodiment describes a bottom-perspective view of a partial chassis 100 (referred to as “chassis 100” throughout a remainder of the present disclosure) of an electric vehicle (EV). The chassis 100 forms the structural backbone of the EV, providing the necessary support for various integral subsystems and components that define the operational capabilities of the EV.
The chassis 100 comprises a closed cradle 102 and an open cradle 104. The closed cradle 102 is a specifically engineered section that securely houses critical components, such as electrical, mechanical and/or electromechanical components associated with operation of the EV. Further, a battery-pack compartment 106 is disposed within the closed cradle 102. The battery-pack compartment 106 is arranged to house the battery pack of the EV. The battery pack stores the electrical energy required for operating the EV. The placement of the battery-pack compartment 106 within the protected environment of the closed cradle 102 ensures safety of the battery-pack compartment 106 while contributing to the balanced weight distribution of the EV. The strategic placement of the battery-pack compartment 106 optimizes the centre of gravity of the EV, thus influencing handling and stability of the vehicle. The design of the closed cradle 102 enables to accommodate the battery-pack compartment 106. Such an enclosed structure ensures a secure environment, safeguarding sensitive components such as the battery pack from environmental factors and potential impacts. The closed cradle enables to provide enhanced protection, contributing significantly to the safety and durability of the EV. Moreover, the enclosed nature of closed cradle 102 not only provides a protection for the battery-pack but also contributes to the overall structural rigidity of the chassis 100, thus playing a vital role in the integrity and resilience associated with the EV.
The chassis 100 further incorporates the open cradle 104. The open cradle 104 refers to a portion of the chassis 100 that offers more accessibility to components stored therein as compared to the closed cradle 102. Further, a powertrain assembly 108 is disposed within the open cradle 104 through at least one mounting point 110. The powertrain assembly 108 includes vital components for propulsion of the EV, such as the electric motor and gearbox. The open cradle 104 enables convenient installation, maintenance, and repair of the powertrain components. Moreover, the open design of cradle 104 allows for more effective cooling of such components, such as, by employing natural airflow from outside the chassis 100 into the chassis 100. It will be appreciated that such effective cooling is crucial for maintaining the optimal performance and prolonging the lifespan of the powertrain assembly 108. Consequently, the open cradle 104 simplifies maintenance activities while enhancing the thermal management of the powertrain assembly 108 of the EV.
The mounting points 110 are integral to the stable and secure placement of the powertrain assembly 108 within the chassis 100. The mounting points 110 ensure the precise positioning and alignment of the powertrain components, which is essential for effective operation and integration of the powertrain components with other systems of the EV. The mounting points 110 further provide a robust foundation for the powertrain assembly 108, enhancing the stability and reliability of the powertrain components within the chassis 100 of the EV.
The powertrain assembly 108 is arranged underneath the battery-pack compartment 106. The positioning of the powertrain assembly 108 underneath the battery-pack compartment 106 within the open cradle 104 contributes significantly to lower the centre of gravity of the EV. The strategic positioning enhances the stability and handling of the EV while also improving the overall dynamics and performance of the EV, making for a smoother and more controlled driving experience.
Figure 2, in accordance with an embodiment describes a top-perspective view of the chassis 100 of Figure 1 with the battery-pack compartment 106 and the powertrain assembly 108 removed. As shown, the chassis 100 comprises a head tube member 200, a vertical downward member 202 extending underneath the head tube member 200, at least one horizontal rearward member 204 extending from the vertical downward member 202 towards a rear end of the chassis 100, a cross member 206 disposed perpendicularly in a downward direction to the at least one horizontal rearward member 204 and a sloped member 208 connecting the at least one horizontal rearward member 204 and the cross member 206. The sloped member 208 is disposed at an angle with respect to the at least one horizontal rearward member 204. The head tube member 200 serves as the frontal anchor element of the chassis 100, providing a pivotal connection to the steering and front wheel assembly. The vertical downward member 202 is a crucial structural element linking the front to the rear of the chassis 100. The vertical downward member 202 is integral to the overall strength and rigidity of the chassis 100, providing a backbone that supports the weight and stress distribution across the EV. The at least one horizontal rearward member 204 form the primary longitudinal support structure, playing a vital role in maintaining the overall shape and integrity of the chassis 100. The at least one horizontal rearward member 204 also contributes to the distribution of weight and balance and is therefore crucial for the handling and stability of the EV. The cross member 206 further strengthens the chassis structure by providing additional support, enhancing the lateral stability of the chassis 100, reducing flex and ensuring that the EV remains stable during different driving conditions. The sloped member 208 enables to create a geometric configuration that contributes to the aerodynamic efficiency and structural dynamics of the EV. The angle of the sloped member 208 influences the aerodynamic profile of the EV, further influencing factors such as wind resistance and fuel efficiency associated with the EV. Optionally, the chassis 100 comprises at least one vertical rearward member 210.
In another embodiment, the head tube member 200, the vertical downward member 202 and the at least one horizontal rearward member 204 define the closed cradle 102. The arrangement of the head tube member 200, the vertical downward member 202 and the at least one horizontal rearward member 204 creates a protected and enclosed space within the chassis 100, which is ideal for housing critical and sensitive components such as the battery pack. The design of the closed cradle 102 is pivotal in ensuring the safety and integrity of the components housed within the closed cradle 102. The enclosed nature of the closed cradle 102 shields the components stored therein from external environmental elements, road debris, and impacts, thereby enhancing the safety and durability of the EV. The configuration of the closed cradle 102 also contributes to the overall structural integrity of the chassis 100, providing a robust foundation that supports the weight of the EV and balances the distribution of forces during operation of the EV.
In an embodiment, the open cradle 104 is defined by at least one of: the at least one horizontal rearward member 204, the cross member 206 and the sloped member 208. The open design of the open cradle 104 offers a versatile and accessible space within the chassis 100, providing an ideal location for the placement of various components, such as the powertrain assembly 108. The accessibility associated with the open cradle 104 allows for ease of installation, maintenance, and repair of the powertrain assembly 108 housed within the open cradle 104. The design of the open cradle 104 is beneficial for the powertrain assembly 108 that may require regular maintenance and potential upgrades throughout the lifecycle of the EV. The open nature of the open cradle 104 also enables efficient cooling of the components associated with the powertrain assembly 108. It will be appreciated that by allowing air to flow around the components of the powertrain assembly 108, the open cradle 104 helps in heat dissipation, which is crucial for maintaining the performance and extending the lifespan of the components of the powertrain assembly 108. Moreover, the strategic placement and design of the open cradle 104 within the chassis 100 contribute to the overall balance and weight distribution of the EV. For example, by housing the powertrain assembly 108 in the open cradle 104, the centre of gravity of the EV is optimized, enhancing handling and stability of the EV especially during high-speed operation and in varying driving conditions.
In another embodiment, the powertrain assembly 108 is mounted on at least one of: the at least one horizontal rearward member 204, the cross member 206 and the sloped member 208. The choice of mounting the powertrain assembly 108 on either the horizontal rearward member 204, the cross member 206, or the sloped member 208 enables the vehicle designer to optimize the position of the powertrain assembly 108 for weight distribution, centre of gravity and overall vehicle dynamics. For example, mounting the powertrain assembly 108 closer to the rear (on the cross member 206) is preferable for certain vehicle designs to improve traction or handling. Conversely, a more forward mounting (on the at least one horizontal member 204) enables to achieve a more balanced weight distribution. Further, the ability to mount the powertrain assembly 108 on the sloped member 208 also offers unique advantages in terms of space utilization and vehicle aesthetics. Consequently, the versatile approach to mounting allows for significant flexibility in the placement and configuration of the powertrain assembly 108. The flexibility in mounting of the powertrain assembly 108 not only impacts the performance of the EV but also aids in maintenance and repair of the EV. It will be appreciated that depending on the chosen mounting position, the accessibility of the powertrain components for service technicians can be greatly enhanced, leading to easier and more efficient maintenance procedures.
In an embodiment, each mounting point comprises a vibration dampening element to reduce transmission of vibrations to the chassis 100. The vibration dampening elements are crucial in enhancing the overall ride quality and comfort associated with the EV. Further, by absorbing and mitigating the vibrations generated by the powertrain assembly 108 during operation, the vibration dampening element prevent the vibrations from being transmitted to the passengers and the rest of the EV, thus resulting in a smoother and quieter ride, which is particularly important in EV where the absence of engine noise makes other sounds more noticeable. Moreover, the reduction of vibrations has a beneficial effect on the longevity and reliability of both the powertrain components and the chassis 100. It will be appreciated that by minimizing the stress and wear caused by the vibrations, the vibration dampening elements contribute to the extended lifespan of powertrain components and reduce the frequency and cost of maintenance.
In another embodiment, the vertical downward member 202 is pivotally connected with the head tube member 200 to alter the volume to accommodate different sizes of the battery-pack compartment 106. The pivotal connection of the vertical downward member 202 with the head tube member 200 enables to adjust the position of the vertical downward member 202, thereby increasing or decreasing the space available for the battery-pack compartment 106. Such adjustability is highly beneficial in electric vehicles where the size of the battery pack can vary significantly depending on the intended range, performance, and other specifications of the EV. Further, allowing for adjustments to accommodate different battery sizes enables to provide a high degree of flexibility in the design and manufacturing of EVs. For example, enabling a single chassis design to be used across multiple vehicle models with varying battery requirements, reduces manufacturing complexity and costs. Furthermore, the adaptability can be advantageous in future-proofing the vehicle design, as it allows for easier upgrades to newer or larger battery packs with the evolution of battery technology. Consequently, the adjustable vertical downward member 202 enhances the versatility and scalability of the design of the EV, making the EV suitable for a wide range of applications and consumer needs.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

,CLAIMS:WE CLAIM:
1. An electric vehicle (EV) comprising:
a chassis (100) comprising a closed cradle (102) and an open cradle (104);
a battery-pack compartment (106) disposed within the closed cradle (102); and
a powertrain assembly (108) disposed within the open cradle (104) through at least one mounting point (110),
wherein the powertrain assembly (108) is arranged underneath the battery-pack compartment (106).
2. The EV as claimed in claim 1, wherein the chassis (100) comprises:
a head tube member (200);
a vertical downward member (202) extending underneath the head tube member (200);
at least one horizontal rearward member (204) extending from the vertical downward member (202) towards a rear end of the chassis (100);
a cross member (206) disposed perpendicularly in a downward direction to the at least one horizontal rearward member (204); and
a sloped member (208) connecting the at least one horizontal rearward member (204) and the cross member (206), wherein the sloped member (208) is disposed at an angle with respect to the at least one horizontal rearward member (204).
3. The EV as claimed in claim 2, wherein the head tube member (200), the vertical downward member (202) and the at least one horizontal rearward member (204) define the closed cradle (102).
4. The EV as claimed in claim 2, wherein the open cradle (104) is defined by at least one of: the at least one horizontal rearward member (204), the cross member (206) and the sloped member (208).
5. The EV as claimed in claim 4, wherein the powertrain assembly (108) is mounted on at least one of: the at least one horizontal rearward member (204), the cross member (206) and the sloped member (208).
6. The EV as claimed in claim 1, wherein each mounting point (110) comprises a vibration dampening element to reduce transmission of vibrations to the chassis (100).
7. The EV as claimed in claim 2, wherein the vertical downward member (202) is pivotally connected with the head tube member (200) to alter the volume to accommodate different sizes of the battery-pack compartment (106).