DESC:ONBOARD CHARGER MOUNTING ON ELECTRIC VEHICLE
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202321090116 filed on 30/12/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to intigration of component on an electric vehicle. Particularly, the present disclosure relates to an onboard charger mounting arrangement for an electric vehicle.
BACKGROUND
Recently, there has been a rapid development in electric vehicles because of their ability to resolve pollution-related problems and serve as a clean mode of transportation. Generally, electric vehicles include a power pack, and/or combination of electric cells for storing electricity required for the propulsion of the vehicles. The electrical power stored in the power pack of the electric vehicle is supplied to the traction motor and various other electrical components for operation of the electric vehicle.
The operational range of the electric vehicle is limited by the capacity of the power pack installed in the electric vehicle. The power pack of the electric vehicle is required to be charged once the state of charge of the power pack depletes. The charging of the power pack would require the AC/DC charging infrastructure. The AC/DC charger is connected to the electric vehicle to charge the power pack. However, there is limited availability of such charging infrastructure. Moreover, in the remote and/or urban areas, the availability of the charging infrastructure becomes negligible.
Presently, the electric vehicles are being made available with an in-line charger that have charging electronics available between the charging gun and the power source connectors (including domestic power outlets) to charge the power pack of the electric vehicle. Moreover, these in-line chargers are bulky and difficult to carry.
Conventionally, existing onboard charger systems typically focus on the efficiency of power conversion, charge management, and safety protocols. However, the one challenge remains exist, such as optimal mounting structure for the onboard charger within the vehicle. Proper mounting is crucial for ensuring the onboard charger’s protection, stability, and efficiency while minimizing space consumption, weight distribution imbalance, and any impact on vehicle aerodynamics.
Thus, there exists a need of mounting arrangement for an onboard charger that overcomes the abovementioned problems.
SUMMARY
An object of the present disclosure is to provide an onboard charger mounting arrangement for an electric vehicle.
In accordance with a first aspect of the present disclosure, there is provided an onboard charger mounting arrangement for an electric vehicle. The mounting arrangement comprises a dual cradle frame, a power pack, a powertrain and an onboard charger. The onboard charger is mounted on the dual cradle frame in a close proximity of the power pack.
The disclosed mounting arrangement places the onboard charger in a position within the frame where airflow is maximized. The onboard charger being mounted on the dual cradle frame, specifically near the upper or cross-frame tubes. The charger is exposed to the natural airflow generated as the motorcycle moves. Thus, mounting arrangement enables the efficient heat dissipation and preventing the onboard charger from overheating. Beneficially, the arrangement improves the performance and life of the charger. Advantageously, the mounting arrangement provides a robust mechanical support and protection for the onboard charger against road vibrations, shocks, and impacts. Thus, reduces the risk of mechanical damage and ensure the consistent performance even in rough driving conditions. Moreover, the arrangement positioned in manner to maintain balanced weight distribution in the vehicle. Which is crucial for enhancing driving stability and vehicle handling. More beneficially, the onboard charger integrated into the vehicle, users no longer need to rely on bulky external in-line chargers. This makes charging more convenient and eliminates the hassle of carrying additional equipment.
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:
Figure 1 is a right side view off a vehicle frame on which an on board charger is being mounted, in accordance with an imbodiment of the present disclosure.
Figure 2 is a exploded view of an onboard charger mounted on the vehicle frame, in accordance with an imbodiment of the present disclosure.
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 from which the arrow is starting.
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 recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the terms, electric vehicle”, “EV”, “EVs” and “vehicle” are used interchangeably and refer to any vehicle powered by one or more electric motors where energy is supplied through onboard energy storage systems such as batteries, supercapacitors, or hydrogen fuel cells. Further, the electric vehicle may include but not limited to, car, trucks, buses, motorcycles, bicycles, motorbikes, and scooters.
As used herein, the terms “dual cradle frame”, and “frame” are used interchangeably and refer to a structural component of the vehicle that consists of two cradle-like sections which hold and support the essential components of the motorcycle, such as a power pack and powertrain. This typically includes multiple interconnected frame tubes that form the upper and lower cradles which provides stability and structural integrity to the motorcycle. The “dual cradle frame” may apply to various types of vehicle frames that incorporate at least two cradles or supports for holding critical vehicle components. The cradles may vary in shape, size, and configuration, depending on the design requirements of different vehicles.
As used herein, the terms “power pack” and “battery” and “energy storage unit” and “combination of cells” refer to a battery system or combination of electric cells which used to store electrical energy that required to power the electric vehicle. This provides the necessary power to operate the vehicle’s powertrain and other auxiliary electrical components.
As used herein, the term “powertrain” and “drivetrain” refers to the components that responsible for converting the electrical energy from the power pack into mechanical energy to propel the vehicle. In the electric vehicle having manual transmission, this typically includes the electric motor, transmission system, gearbox, and related electronics such as the motor controller (DTU) and so forth.
As used herein, the term “Onboard Charger” and “OBC” and “charger” are used interchangeably and refers to a device integrated into the vehicle that allows the battery (power pack) to be recharged by converting alternating current (AC) from external power sources into direct current (DC) that suitable for charging the vehicle’s battery. The onboard charger may include but not limited to AC level 1, AC level 2, or even DC fast charging and may implemented in various vehicle configurations.
As used herein, the term “head member” refers to the front section or top portion of the dual cradle frame. This typically serves as a structural point for mounting or securing other components, including the front fork or steering assembly.
As used herein, the terms “bottom member” refers to the lower structural part of the dual cradle frame, supporting the lower components of the vehicle, including parts of the powertrain or other systems mounted below the upper frame.
As used herein, the term “frame tube “refers to the cylindrical or tubular structural elements that make up the frame of the vehicle. This forms the skeleton of the dual cradle frame, providing rigidity, strength, and support to the vehicle while housing various components such as the power pack and powertrain.
As used herein, the term “upper cradle” refers to the portion of the dual cradle frame designed to support and secure the power pack. This section is typically located in the upper part of the frame, ensuring that the power pack is held firmly in place.
As used herein, the terms “lower cradle” refers the part of the dual cradle frame where the powertrain (such as the electric motor) and/or power pack is mounted. This provides a stable and secure platform for housing the vehicle's propulsion system.
As used herein, the terms “upper frame tubes” refers to the frame tubes located in the upper part of the dual cradle frame and forming part of the structural support system for the upper cradle.
As used herein, the terms “middle frame tubes” refers to the intermediate tubes in the frame structure, which may connect the upper and lower frame tubes and provide additional structural support to the overall frame.
As used herein, the terms “lower frame tubes” refer to the tubes which are positioned at the bottom of the frame and forming part of the lower cradle where the powertrain and/or power pack is mounted. These tubes help to support the weight of the powertrain and provide rigidity to the lower structure of the vehicle.
As used herein, the terms “cross frame tubes” refer to the transverse tubes that connect different sections of the dual cradle frame and providing additional rigidity and strength to the frame. These tubes help to maintain the structural integrity of the frame under dynamic loads.
As used herein, the terms “mounting brackets” and “brackets” are used interchangeably and refer to the structural elements which used to secure the onboard charger to the frame tubes (such as the upper and lower frame tube and cross-frame tube). These brackets provide stability and ensure that the charger remains securely attached to the frame during operation.
Referring to figure 1, in accordance with an embodiment describes a schematic view of an onboard charger mounting arrangement for an electric vehicle. The mounting arrangement comprises a dual cradle frame 100, a power pack (not shown in fig), a powertrain (not shown in fig), and an onboard charger 102. The onboard charger 102 is mounted on the dual cradle frame 100 in a close proximity of the power pack (not shown in fig).
The dual cradle frame 100 enhances structural rigidity of the frames than single cradle frames. The double cradle support allows the efficient distributing of weight and stress across the frame 100. The dual cradle frame 100 comprises a head member 104 that provides rigidity to the frame, even in high-stress areas near the front of the vehicle, where forces from steering, braking, and vibrations are concentrated. Further, ensures the proper alignment between the upper and lower sections of the dual cradle frame 100 and also ensures the alignment of the charger 102 is maintained relative to other components such as the power pack and powertrain thus, contributing to the overall structural stability.
The dual cradle frame 100 comprises a bottom member 106 that provides structural support for the lower section of the dual cradle frame 100 and providing reinforcement to the entire frame structure. The structural reinforcement ensures that the frame 100 maintains its rigidity under dynamic conditions such as acceleration, braking, and cornering. This rigidity creates a stable foundation for the onboard charger 102. Thus, minimizing the risk of excessive movement or vibrations that may damage the charger 102 or reduce its efficiency. In an example, the bottom member 106 is fabricated high-strength materials such as steel or aluminium alloys to withstand operational stresses and thermal expansion.
The dual cradle frame 100 comprises a plurality of frame tubes that being configured to form an upper cradle 108 and a lower cradle 110.
The upper cradle 108 provides a structural integrity and support for mounted components such as onboard charger 102 and contributing to the proper arrangement. The upper cradle 108 allows secure housing for the power pack (not shown in fig) and ensures that the onboard charger 102 efficiently positioned in close proximity to the power pack (not shown in fig) without any interference. This proximity allows for shorter electrical connections between the power pack (not shown in fig) and the charger 102 thus minimize the power losses and ensures the efficient charging. Further, ensures, the frame 100 can withstand various forces such as vibrations, road shocks, and dynamic loads. The upper cradle 108 provides better stability which is crucial for reducing wear and tear on the charger 102 and its mounting brackets, thereby extending the operational life of the onboard charger 102. Furthermore, upper cradle 108 allows for efficient space utilization which enables the onboard charger 102 to be mounted in a compact and accessible location. This space optimization ensures that the charger 102 is mounted near the power pack (not shown in fig) and contributing to improved electrical efficiency and ease of access for maintenance. In an example, the upper cradle 108 is fabricated with lightweight yet strong materials, such as high-strength steel alloys or aluminium which provide both durability and reduced weight for the vehicle.
The lower cradle 110 provides structural support for the powertrain (not shown in fig) including the motor, transmission, and other drivetrain components and ensures that the powertrain (not shown in fig) securely mounted within the frame 100. Thus, improved stability of the overall frame even during high-stress conditions like acceleration, braking, and cornering. This stability prevents vibrations or structural flexing from affecting the mounting points of the onboard charger 102 located in the upper section of the frame. The stable powertrain also frees up space for optimal placement of the charger 102. The lower cradle 110 efficiently distribute the vehicle's weight and the load from the powertrain evenly across the frame 100. This load distribution prevents stress concentration in any one area of the frame 100 thus improving durability. Further, lower cradle 110 being positioned near the base of the vehicle that provides protection against impacts from road debris or during minor collisions and ensures that the powertrain and related components remain safe from external damage.
In an embodiment, the plurality of frame tubes comprises a pair of upper frame tubes 112, a pair of middle frame tubes 114, and a pair of lower frame tubes 116.
The pair of upper frame tube 112 ensures the proper mounting arrangement of the onboard charger 102. The upper frame tube 112 serves as a primary mounting point for the onboard charger 102 and ensures the charger 102 is securely mounted to the frame 100. The tube's rigid structure helps to maintain a stable mounting surface and preventing the charger 102 from shifting during operation or while riding.
The pair of middle frame tubes 114 provides support and connectivity between the upper cradle 108 and lower cradle 110 of the frame 100 and contributing to the structural integrity and mounting arrangement of key components, including the onboard charger 102. Further, ensures the upper and lower frame sections remain aligned and rigid. The middle frame tube 114 prevents any deformation or misalignment of the onboard charger 102 mounting points, thereby maintaining a secure and stable mounting arrangement. Furthermore, efficiently distributes the mechanical loads generated during vehicle operation, such as vibrations, impacts, and the weight of mounted components and ensures that these loads are spread across the frame 100, thus reduces the risk of stress on the mounting brackets that secure the onboard charger 102. This ensures that the charger 102 remains properly mounted and reduces the fatigue or failure of the frame or mounting points over time.
The pair of lower frame tubes 116 provides structural support to the vehicle, including housing critical components such as powertrain (not shown in fig) and contributing to the overall stability that ensures the proper mounting of the onboard charger 102. Further provides proper alignment and rigidity to the frame 100 and ensuring that both the upper and lower sections remain properly aligned during vehicle operation. The rigidity of the lower frame tube 116 helps to maintain the structural integrity of the entire frame 100, including the points where the charger 102 is mounted.
In an embodiment, the upper cradle 108 is configured to accommodate the power pack (not shown in fig).
The upper cradle 108 comprises a plurality of cross-frame tubes 118 that provides structural support to the dual cradle frame 100 and ensuring that the upper cradle 108 remains rigid and stable under dynamic loads. Further increases the torsional stiffness of the frame 100 which means frame 100 is more resistant to twisting forces that occur during sharp turns or acceleration. The cross-frame tube 118 contributes to maintaining proper alignment of the upper cradle 108 and the entire dual cradle frame 100. The proper frame alignment ensures that the onboard charger 100 mounting points are precisely positioned.
In an embodiment, the lower cradle 110 is configured to accommodate the powertrain (not shown in fig) including motor, transmission, and other drivetrain components and ensures that the powertrain (not shown in fig) securely mounted within the frame 100.
Referring to figure 2 in accordance with an embodiment describes a schematic view of an onboard charger mounting arrangement for an electric vehicle. The mounting arrangement comprising, onboard charger 102 being mounted on the upper frame tube and the cross-frame tube via a plurality of mounting brackets 120.
In an embodiment, a first pair of mounting brackets from the plurality mounting brackets 120 are connected on the upper frame tube 112.
In an embodiment, a second pair of mounting brackets from the plurality mounting brackets 120 are connected on the cross-frame tube 118.
The mounting brackets 120 securely attach the onboard charger 102 to the frame 100 and provides stable connection between the charger 102 and the frame 100. The brackets 120 ensure that the charger 102 doesn’t move or shift during vehicle operation thus, minimizing the risk of damage or misalignment. The brackets 120 allow the onboard charger 102 to be easily mounted in the correct position with standardized attachment points and make maintenance or replacement more convenient thus, minimizes downtime and easy for servicing. Beneficially, the brackets 120 prevent excessive force from acting on a single point of the charger 102 or frame 100. This enhances the durability of the mounting arrangement and reduces the risk of failure or damage under load. The mounting brackets 120 are structurally designed that are easy for installation and removal. Thus, makes it easier to service, replacement, or adjust the onboard charger 102 without requiring extensive disassembly and allows easy access to the charger 102 for routine maintenance thus, contributes to the overall reliability of the system. In an example, the mounting brackets 120 is fabricated high-strength materials such as steel or aluminium alloys to withstand operational stresses and provide durability and reduced weight for the vehicle.
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 combinations 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”, and “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.
,CLAIMS:WE CLAIM:
1. An electric vehicle, comprising: a dual cradle frame (100); a power pack; a powertrain and an onboard charger (102), wherein the onboard charger 102 is mounted on the dual cradle frame (100) in a close proximity of the power pack.

2. The electric vehicle as claimed in claim 1, wherein the dual cradle frame (100) comprises a head member (104), a bottom member (106) and a plurality of frame tubes configured to form an upper cradle (108) and a lower cradle (110).

3. The electric vehicle as claimed in claim 2, wherein the plurality of frame tubes comprises a pair of upper frame tubes (112), a pair of middle frame tubes (114), and a pair of lower frame tubes (116).

4. The electric vehicle as claimed in claim 2, wherein the upper cradle (108) is configured to accommodate the power pack.

5. The electric vehicle as claimed in claim 2, wherein the lower cradle (110) is configured to accommodate the powertrain.

6. The electric vehicle as claimed in claim 1, wherein the upper cradle (108) comprises a plurality of cross-frame tubes (118).

7. The electric vehicle as claimed in claim 1, wherein the onboard charger (102) is mounted on the upper frame tube (112) and the cross-frame tube (118) via a plurality mounting brackets (120).

8. The electric vehicle as claimed in claim 1, wherein a first pair of mounting brackets from the plurality mounting brackets are connected on the upper frame tube (112).

9. The electric vehicle as claimed in claim 1, wherein a second pair of mounting brackets from the plurality mounting brackets are connected on the cross-frame tube (118).