DESC:FIELD OF INVENTION
[001] The present invention relates to a system for housing a controller of an electric vehicle. More particularly, the present invention relates to a controller housing for an electric vehicle with compact design and natural air-cooling mechanism.

BACKGROUND OF THE INVENTION

[002] A motor controller in an electrical vehicle serves to connect a motor and a battery. The motor controller regulates the flow of electrical energy from the battery to the electric motor, controlling speed and force. It plays a crucial role in the vehicle’s performance and efficiency.

[003] Conventionally known controllers face various problems such as overheating, voltage instability, software glitches etc. Overcoming these challenges is crucial for maintaining optimal performance and ensuring reliability of the vehicle. For instance, in a drive inverter overheating can occur, leading to reduced efficiency and potential damage to the vehicle. In Gen4size 10 type of motor controller, voltage instability affects motor’s performance, and in brushless motor controllers, software glitches may affect overall performance. These problems may be addressed by improving thermal management, voltage regulation and firmware updates.

[004] Currently known systems for enhancing thermal efficiency may include liquid cooling systems such as a coolant based on ethylene glycol and water (EGW), or an oil based coolant, for dissipating heat energy. Such systems of the prior art are complicated and expensive.

[005] Alternatively, advanced materials may also be used for enhanced heat dissipation. Reference may be made to the Australian patent number AU2007267926B2 that discloses an electric device, such as an electric motor, a generator, or a regenerative motor, having a wound stator core made from advanced low-loss material. In preferred embodiments, the electric device is an axial airgap-type configuration. The invention provides an electric device having a high pole count that operates at high commutating frequencies, with high efficiency and high torque and power densities. Advanced low-loss materials exploited by the present invention include amorphous metals, nanocrystalline metals, and optimized Fe-based alloys. Use of advanced materials, however, makes the system expensive.

[006] Therefore, keeping in view the problems associated with the state of the art there is a need to devise better placement of a controller in the electric vehicle having compact design, economical, better heat dissipation and natural air cooling system.

OBJECTIVES OF THE INVENTION

[007] A primary objective of the present invention is to provide system and method for efficient heat dissipation for a motor controller of an electric vehicle.

[008] Another objective of the invention is to provide a housing for an electric vehicle controller that enables better heat dissipation, safe placement and efficient space utilization.

[009] Another objective of the present invention is to provide an electric vehicle controller housing configured at height at a safer height from the ground level, thereby safeguarding the bottom part from water pool.

[0010] Another objective of the present invention is to provide a housing for controller of an electric vehicle, wherein the controller is positioned near the battery and the motor of the electric vehicle, thereby reducing electric power losses.

[0011] Yet another objective of the present invention is to provide an electric vehicle controller housing comprising of an efficient cooling arrangement for cooling of the Controller.

[0012] Other objects and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a system for housing a controller of an electric vehicle having compact design and natural air-cooling mechanism. Specifically, the present invention relates to a system for housing a controller of a two wheeler electric vehicle comprising a heat dissipation mechanism and unique placement. In a preferred embodiment, the controller housing comprises a floor board fixed at a footrest on front end of the electric vehicle, an internal compartment provided beneath the floor board, a controller detachably fixed inside the internal compartment and connected to a battery and a motor of the electric vehicle, comprising a plurality of fins and a removable harness cover provided on the sides of the internal compartment to cover the controller from external conditions.

[0014] The controller regulates and optimizes the flow of power from the battery to the motor. Further, the controller placed inside the electric vehicle includes a plurality of fins on lower side of the controller, thereby helps in cooling of the controller and natural draft of air enters from the slots of the harness cover provided in front side of the vehicle.

BRIEF DESCRIPTION OF DRAWINGS

[0015] An understanding of the present invention may be obtained by reference to the accompanying drawings, when taken in conjunction with the description herein, in which:

[0016] Figure 1 illustrates exploded view of the electric vehicle controller housing;

[0017] Figure 2 illustrates the position of the housing for accommodating controller in a two-wheeler electric vehicle according to an embodiment of the present invention;

[0018] Figure 3 illustrates the Controller provided with a plurality of fins;

[0019] Figure 4 illustrates the front side of the housing, wherein the harness cover is provided; and

[0020] Figure 5 illustrates the natural air circulation system in the electric vehicle controller housing.

[0021] Reference Numerals for the components of the electric vehicle controller housing are enlisted herein:

Sr. No. Component Reference Numeral
1 Housing for a Controller of an Electric Vehicle 100
2 Floor Board 101
3 Harness cover 102
4 Controller 103
5 Plurality of channels 104
6. Plurality of slots 105
7. Plurality of fins 106
8. Internal compartment 107

DETAILED DESCRIPTION OF INVENTION

[0022] The following description describes various features and functions of the disclosed assembly with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed assembly can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.

[0023] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0024] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
[0025] The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purposes only and not for the purpose of limiting the invention.

[0026] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0027] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. The equations used in the specification are only for computation purpose.

[0028] Accordingly, the present invention relates to a system for housing a controller of an electric vehicle. More particularly, the present invention relates to a controller housing for an electric vehicle with compact design and natural air-cooling mechanism.

[0029] According to an aspect of the present invention, a system for housing controller of an electric vehicle is provided for efficient heat dissipation and minimum power losses. The controller housing of an electric vehicle comprises a floor board fixed at a footrest on front end of the electric vehicle, an internal compartment provided beneath the floor board, a controller detachably fixed inside the internal compartment and connected to a battery and a motor of the electric vehicle, comprising a plurality of fins and a removable harness cover provided on the sides of the internal compartment to cover the controller from external conditions.

[0030] As per preferred embodiment and as illustrated in Figure 1 & 2, an electric vehicle controller housing (100) of an electric two-wheeler vehicle comprising a floor board (101) fixed at a footrest on front end of the electric vehicle; an internal compartment (107) provided beneath the floor board (101); a controller (103) detachably fixed inside the internal compartment (107) and connected to a battery and a motor of the electric vehicle; and a removable harness cover (102) provided on the sides of the internal compartment (107) to cover the controller (103) from external conditions. As illustrated in Figure 4, the harness cover (102) consists of plurality of linear slots (105) or louvers on the front side of the vehicle for entry of air from the surrounding.

[0031] In the preferred embodiment, the controller (103) includes a plurality of fins (106) provided on lower side of the controller (103) for cooling and natural draft of air. The air enters from the front side of the vehicle through the louvers or slots (105) provided on harness cover (102) due to movement of the vehicle, and passes from one side of the controller housing to its other side and exits from rear side of the vehicle as shown in Figure 5.

[0032] The two-wheeler vehicle is an electric two-wheeler. In an alternative embodiment, the two wheeler may also be selected form but not limited to petrol based two-wheeler or diesel based two wheeler.

[0033] In an alternate embodiment, the shape of slots (105) provided at the harness cover (102) may be parabolic or U-shaped.

[0034] Specifically, the vehicle controller housing configured at height more than 250 mm from the ground level, thereby safeguarding the bottom part from water pool.

[0035] Moreover, in accordance with the present invention, in the electric vehicle controller housing (100), the controller (103) is positioned near the battery and the motor of the electric vehicle, thereby reducing electric power losses.

[0036] The functioning of the various components/parts of the electric vehicle controller housing (100) is described below:

1) Floor-Board: The floor-board (101) is configured at top of the electric vehicle controller housing (100). The floor-board (101) covers the top area of the housing, thereby providing fully covered housing and protection from the thefts.
2) Internal compartment: The internal compartment (107) provided beneath the floor board for covering the controller such that the controller is safe from external environment.

3) Harness cover: The harness cover (102) is configured in front side of the electric two–wheeler vehicle. The harness cover (102) consists of a plurality of linear slots (105) for entry of air from the surroundings.

4) Controller: The controller (103) is detachably fixed in the housing connected to a battery and a motor of the electric vehicle. The controller (103) regulates and optimizes the flow of power from the battery to the motor. Further, as illustrated in Figure 3, the controller (103) placed inside the electric vehicle includes a plurality of fins (106) on lower side of the controller (103), thereby helping in cooling of the controller (103) and natural draft of air entering from the slots (105) of the harness cover (102) provided in front side of the vehicle.

5) Plurality of channels: The plurality of channels (104) is provided at the back of the housing. The air entering from the slot of harness cover (102) naturally cools the controller (103) and then the hot air escapes from the plurality of channels (104) provided at the back of the housing (100), thereby providing natural air-cooling system for the controller housing (100). The natural air-cooling system is clearly shown in Figure 5 of the present invention.

TECHNICAL ADVANTAGES OF THE PRESENT INVENTION

[0037] The present invention exhibits following advantages:
1) The present invention provides a system for cooling the controller, wherein the controller is placed below a luggage area provided at the bottom part of rugged frame structure of the electric vehicle for better space utilization.
2) In the disclosed electric vehicle, the controller housed in the housing consists of a plurality of fins for cooling of the controller.
3) The disclosed housing is configured at height more than 250 mm from the ground level, thereby safeguarding the bottom part from water pool.
4) The present invention discloses a housing which is fully covered, thereby providing protection from thefts.

[0038] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
,CLAIMS:WE CLAIM:

1. A controller housing (100) for an electric vehicle, comprising:
a) a floor board (101) fixed at a footrest on front end of the electric vehicle;
b) an internal compartment (107) provided beneath the floor board (101);
c) a controller (103) detachably fixed inside the internal compartment (107) and connected to a battery and a motor of the electric vehicle; and
d) a removable harness cover (102) provided on the sides of the internal compartment (107) to cover the controller (103) from external conditions;
wherein,
i. the harness cover (102) comprises a plurality of linear slots (105) configured to pass surrounding air inside the internal compartment; and
ii. the controller (103) comprises a plurality of fins (106) on lower side for cooling and natural draft of air.

2. The controller housing (100) as claimed in claim 1, wherein the vehicle is a two-wheeler vehicle.

3. The controller housing (100) as claimed in claim 2, the two-wheeler vehicle is selected from petrol-based two-wheeler, diesel-based two-wheeler, and electric two-wheeler.

4. The controller housing (100) as claimed in claim 1, wherein the shape of the slots (105) provided at the harness cover (102) may be parabolic or U-shaped.

5. The controller housing (100) as claimed in claim 1, wherein the controller housing (100) is configured at height more than 250 mm from the ground level.