Description:FIELD OF INVENTION

The present invention concerns a cradle system to provide a structural and positioning frame for mounting automotive powertrain and other drive components thereon. In particular, the present invention concerns a structural and positioning frame for mounting an Electric Powertrain (EPT) and other drive components thereon. More particularly, the present invention concerns a cradle system to mount EPT and other drive components thereon.

BACKGROUND OF THE INVENTION

In recent years, the industry in general and the mobility industry in particular is going through a lot of upheavals, especially regarding its ever increasing dependence on non-conventional energy sources like electric and solar energy and from the conventional fossil fuels like petrol, diesel, CNG etc.

The automotive industry is particularly adapting the non-conventional energy sources for running of automobiles, i.e. the internal combustion engines are being replaced with electrically driven solutions due to continuous improvements in electrical energy storage in more compact batteries and energy storage devices.

The automotive vehicles running on IC-Engines consuming fossil fuels like petrol, diesel, CNG etc. are converted into electrically driven vehicles by replacing the IC-engine with the Electric Powertrain (EPT) which is a major carryover component of electric-drive, which includes Power Distribution Unit (PDU), Telematics Control Unit (TCU), Out-Board Charger (OBC), DC-DC Converter, HVAC Compressor, Chiller Unit and Water Pump. However, the Power Distribution Unit (PDU) and DC-DC Converter require an additional cradle for mounting thereof, because there is no scope for any modifications in the aforesaid EPT as well as at the vehicle’s body side.
Therefore, there is an existing need for providing a structural and positioning frame to mount the Electric Powertrain (EPT) which eliminates the requirement of an additional cradle to mount and support the Power Distribution Unit (PDU) and DC-DC Converter.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide an improved structural and positioning frame for the Electric Powertrain (EPT), which has a cradle for supporting all drive components thereof.

Another object of the present invention is to provide an improved structural and positioning frame for the Electric Powertrain (EPT) which has a superstructure, which eliminates the need for an additional cradle to mount the drive components thereon.

Still another object of the present invention is to provide an improved structural and positioning frame for the Electric Powertrain (EPT) which has a cradle with optimized weight and cost.

Yet another object of the present invention is to provide an improved structural and positioning frame, which reduces the welding thereon to prevent deterioration thereof.

An additional object of the present invention is to provide a compact cradle system for accommodating and mounting various components of the Electric Powertrain (EPT) within the existing installation space in the BIW by stacking them at different levels.
These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

DESCRIPTION OF THE INVENTION

In accordance with the present invention, a structural and positioning frame is configured as a cradle system for mounting an electric powertrain (EPT) and other drive components thereof.

This cradle system includes a novel superstructure, to support all components of the electric powertrain (EPT), such as Power Distribution Unit (PDU), Telematics Control Unit (TCU), Outboard Charger (OBC), DC-DC Converter, HVAC Compressor, Chiller Unit and Water Pump.

This cradle system is configured to install EPT drive components in a multi-stage structure and thus forms a compact assembly to facilitate an easy installation into and removal from the vehicle during assembly and maintenance thereof.

In addition, the cradle system isolates the vibrations from reaching the BIW by isolating electric powertrain (EPT) assembly, compressor, and chiller unit using rubber mounts. This cradle system also supports various electrical wirings and cooling hoses, and is rigidly fastened to the vehicle body side-rails from the bottom.

This novel cradle system is made as a superstructure to accommodate four (4) major electrical components e.g. TCU, PDU, OBC and DC-DC converter in a multi-stage structure for substantial space saving, which is a scarce commodity within the BIW. This EPT is supported from the cradle bottom, the TCU and OBC are supported from the top and the additional hollow rectangular columns are welded on the cradle top to support the PDU and DC-DC converter. Major sub-components of cradle system are made of circular and rectangular tubes.

SUMMARY OF INVENTION

In accordance with the present invention, there is provided a cradle system for mounting electric powertrain of an electric vehicle, the cradle system comprises a lightweight tubular structural and positioning frame thereof for ease of assembly, repair and/or replacement of the electric powertrain and other drive components thereof, wherein the electric powertrain (EPT) and other drive components such as DC-DC converter, power distribution unit (PDU), out board charger (OBC), HVAC compressor, chiller unit, water pumps, telematics control unit (TCU) and/or the corresponding electrical cable/s and/or hydraulic lines therebetween, are all disposed in a multi-stage structure from the top and/or under the base of the cradle structure for ease of assembly, repair and/or replacement of the EPT and DC-DC Converter, PDU, OBC, HVAC Compressor, Chiller Unit, Water Pumps, and TCU and the like.

In a preferred embodiment of the present invention, the structural and positioning frame of the cradle system comprises:

• a base frame having front and rear members of circular cross-sections and left-side and right-side members of C-in-C sections as well as two middle members of tubular cross-sections, forming a lightweight tubular structure;

• a plurality of vertical members fitted with a bracket and a tubular member to support the DC-DC converter thereon;

• a plurality of vertical members of same height and horizontal cross-members to support the PDU thereon;
• a pair of brackets welded on the front and rear members of the base frame, and another pair of brackets welded on the left-side and right-side members;

• a bracket welded on the front member to support the HVAC compressor thereon;

• a bracket welded on the front member to mount the chiller unit thereon;

• a plurality of brackets welded to the base frame to support the EPT thereon;

• and a pair of brackets to mount water pumps thereon; and

• a plurality of brackets to support the TCU thereon;

wherein the cradle system is isolated from motor vibrations generated in the electric powertrain (EPT) by the rubber mounts, and from the vibrations generated in the HVAC compressor by the rubber bushes.

Typically, the cradle system is mounted along with the drive components such as DC-DC Converter, Power Distribution Unit (PDU), Outboard Charger (OBC), HVAC Compressor, Chiller Unit, Water Pumps, Telematics Control Unit (TCU), and the EPT, by fastening the cradle system within the body-in-white by four brackets welded on the left-side and right-side members.

Typically, the EPT is mounted from under the base frame of the cradle system and supported on the brackets welded to the base frame.

Typically, the rubber mounts are disposed on the brackets and mounted between the electric powertrain (EPT) and cradle system to prevent the motor vibrations from reaching the cradle system.

Typically, the rubber bushes are disposed between the HVAC Compressor and cradle system to prevent the vibrations of the HVAC compressor from reaching the cradle system.

Typically, the bracket is a detachable bracket configured substantially triangular and fastened on the vertical member by means of a plurality of fasteners.

Typically, the tubular member is a detachable member profiled to connect the vertical members tightened on top thereof by means of a pair of fasteners.

Typically, the base frame comprises a front and rear cylindrical longitudinal member each, two cylindrical middle members as well as two cross-members of C-in-C sections respectively.

Typically, the vertical members are configured with the same height and the vertical member is made smaller than the vertical members to be fitted with the rear end of the profiled tubular member thereon and the front end thereof fitted on the vertical members to combinedly support the DC-DC Converter thereon.

Typically, the profiled tubular member comprises a pair of mounting brackets welded on top thereof and another pair of mounting brackets laterally welded on the inner side of the tubular member to support the DC-DC Converter thereon.

Typically, a pair of seats are welded on the cross-member and another pair of perforated washers are welded on the cross-member for fastening the PDU supported on the cross-members.

Typically, the rubber mounts are disposed between the brackets and electric powertrain (EPT) for isolating the motor vibrations generated therein from reaching the cradle system.

Typically, the rubber bushes are disposed between the bracket and compressor for isolating vibrations generated therein from reaching the cradle system.

Typically, the brackets are welded outside the side members of the base frame for fastening of the cradle system along with the electric powertrain (EPT) and other drive components accommodated within the siderails of the BIW from the bottom-side thereof.

Typically, the heights of the vertical members and the lengths of the horizontal cross-members are optimized to accommodate the electric powertrain (EPT) and other drive components such as DC-DC Converter, Power Distribution Unit (PDU), Outboard Charger (OBC), HVAC Compressor, Chiller Unit, Water Pumps, Telematics Control Unit (TCU) of the EPT within the existing space available inside the BIW.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described in the following with reference to the accompanying drawings.

Figure 1 shows a perspective view of the structural and positioning frame which is configured as a cradle system for mounting electric powertrain (EPT).

Figure 2 shows a top view of the cradle system configured in accordance with the present invention and shown in figure 1.
Figure 3a shows the cradle system configured in accordance with the present invention and shown in figures 1-2 mounted with different components of the Electric Powertrain (EPT) thereon. A portion of the cradle system is encircled as detail “A” explained below with reference to figure 5 showing an exploded view of this portion “A” without EPT drive components mounted thereon.

Figure 3b shows cradle system configured in accordance with the present invention and shown in figures 1-2 and depicting the rubber mounts of the Electric Powertrain (EPT) mounted thereon, when seen from vehicle top.

Figure 4 shows the cradle system configured in accordance with the present invention in the structural and positioning frame for mounting the electric powertrain and other drive components thereon. It includes the connections between various components and/or sub-assemblies thereof.

Figure 5 shows a partially exploded view of encircled detail “A” of the cradle system configured in accordance with the present invention and as shown in Figure 3a, which is mounted without the EPT drive components thereon.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, the cradle system configured in accordance with the present invention for mounting all drive components of the electric power train will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention.

Figure 1 shows a perspective view of the structural and positioning frame which is configured as a cradle system for mounting electric powertrain (EPT) and other drive components of an electric vehicle, and includes a base frame (BF) having a front member 1a and a rear member 1b, both having cylindrical cross-sections; and a left-side member 2a and a right-side member 2, both having a C-in-C section; as well as two cylindrical middle members 3,14; all together forming a lightweight tubular structure The longitudinal members 1a and 1b are made of cylindrical tubes and a plurality of vertical members 7a, 7b, 7c, 7d, 7e, 7f, 7g as well as horizontal cross-members 7h, 7i are made of square tubes. The making of all these members does not use any blanking and forming dies. The other cross-members 2a and 2b are also made of square tubes, which facilitates using common blanking, forming, and trimming dies therefor. This unique configuration of the cradle system reduces the overall production cost and keeps the investment in dies cost very low.

Figure 2 shows a top view of the cradle system 100 configured in accordance with the present invention and shown in figure 1. The superstructure with cradle system 100 having tubular (cylindrical and square) components thereof easily accommodates the maximum number of components of the electric drive. The cradle system 100 comprises a base frame (BF) having two front and rear longitudinal members 1a, 1b and two tubular middle members 3, 14 having cylindrical cross-sections, as well as two left-side and right-side members 2a, 2b having C-in-C sections. The front and rear members 1a, 1b are similar and the right and left cross-members 2a, 2b are also similar. The electric powertrain (EPT) (60) is supported on three brackets 4a, 4b, 4c welded to the base frame (BF). The electric powertrain (EPT) (60) is isolated from the cradle 100 with the help of rubber mounts 200 which stop the motor vibrations to reach the cradle 100. Another component producing vibrations is HVAC compressor 40 mounted on the cradle 100 at another bracket 12d and vibrations produced thereon are isolated by means of rubber bushes disposed in-between the cradle 100 and HVAC compressor 40 to stop its vibrations to reach the cradle system 100. Telematics Control Unit (TCU) 90 and Outboard Charger (OBC) 30 are also mounted on the base frame BF. The bracket 12d is welded on the front member 1a for mounting of HVAC compressor 40. TCU 90 is mounted on four brackets 5a, 5b, 5c, 5d; and OBC 30 on brackets 6a, 6b, 6c, 6d. The brackets 6a, 6b, 6c, 6d support the OBC 30 thereon. TCU 90 controls wireless tracking, diagnostics, and communication to and from the electric vehicle and OBC is the power electronics device in electrically driven vehicles to convert alternating current (AC) power received from the external sources like residential electric supply outlets to direct current (DC) power to charge the battery pack of the automotive vehicle. DC-DC converter 10 and Power Distribution Unit (PDU) 20 are mounted above TCU 90 and OBC 30 on this cradle 100 made of members 7a, 7b, 7c, 7d, 7e, 7f, 7g, 7h, 7i, 8, 9. The vertical members 7a, 7b, 7c are fitted with bracket 8 and tubular member 9 to support the DC-DC Converter 10 thereon. The vertical members 7d, 7e, 7f, 7g have the same height and the horizontal cross-members 7i, 7h support the PDU 20 thereon The horizontal cross-members 7i and 7h have tubular square sections same as the vertical members supporting the PDU 20, which is a high-voltage power supply to distribute the battery power to high-voltage components of the electric vehicle and DC-DC converter 10 changes DC power from an on-board 200-800V high voltage battery into lower DC voltages (48V or 12V) to power headlights, interior lights, wiper and window motors, fans, pumps and many other systems within electric vehicles. The seats 20a, 20b are welded on the cross-member 7i and two perforated washers 20c, 20d are welded on other cross-member 7h for fastening the PDU 20 supported on the cross-members 7i, 7h. Other profiled members, e.g. a triangular bracket 8 fastened on vertical member 7d by fasteners 17, 18 and a profiled tube 9 bolted to vertical members 7a-7b tightened on top thereof by fasteners 18, connect the vertical members 7a, 7b. The vertical members 7a, 7b have the same height and vertical member 7c is smaller than the members 7a, 7b for fitting the rear end of the tubular member 9 thereon and for fitting its front end on the vertical members 7a, 7b for supporting together the DC-DC converter 10 thereon. This bracket 8 and tubular member 9 are configured to be detachable and support the DC-DC converter 10 for facilitating an easy assembly of TCU 90 thereto. The tubular member 9 is welded which has two mounting brackets 9a, 9b on top thereof and another pair of mounting brackets 9c, 9d is laterally welded on the inner side of the tubular member 9 for supporting the. DC-DC Converter 10 thereon. The detachable fastening of bracket 8 and tubular member 9 makes the assembly of TCU 90 easier, as compared to welding which makes the TCU 90 assembly quite difficult. A third bracket 12c is provided for mounting of chiller unit 50 and brackets 12a and 12b are for mounting of water pumps 70, 80 thereon. The bracket 12c is welded on the front member 1a for mounting the chiller unit 50. The cradle system 100 mounted with all the drive components is assembled on the electric vehicle front end body from the bottom thereof. The complete cradle system 100 mounted with the above drive components is fastened to body siderails with the help of four brackets 13a, 13b, 13c, 13d welded on the left-side and right-side members 2a, 2b.

Figure 3a shows the structural and positioning frame with a cradle system 100 configured in accordance with the present invention and shown in figures 1-2 mounted with different components thereon. The cradle system 100 supports DC-DC Converter 10, Power Distribution Unit (PDU) 20, Outboard Charger (OBC) 30, HVAC Compressor 40, Chiller Unit 50, Electric Power Train (EPT) 60, Water Pumps 70, 80, and Telematics Control Unit (TCU) 90.

Figure 3b shows the cradle system 100 configured in accordance with the present invention and depicting the rubber mounts 200 of the Electric Power Train (EPT) mounted thereon and HVAC Compressor 40 and Electric Power Train (EPT) 60 are visible, when seen from top of the vehicle. The other components like DC-DC Converter 10, Power Distribution Unit (PDU) 20, Outboard Charger (OBC) 30, Water Pumps 70, 80, and Telematics Control Unit (TCU) 90 are not shown here for sake of clarity of the structure of the cradle system 100. The horizontal cross-members 7h, 7i are made of square tubes, without using any blanking and forming dies. The cross-members 2a, 2b are also made of square tubes to allow common blanking, forming, and trimming dies therefor. The cradle system 100 has two similar cylindrical front and rear longitudinal members 1a, 1b; two similar cross-members 2a, 2b; and two tubular middle members 3, 14 in the base frame thereof. The EPT 60 is mounted from under the base frame BF and supported on three brackets 4a, 4b, 4c welded to the base frame. The EPT motor vibrations are isolated from the cradle system 100 by three rubber mounts 200, which stop these motor vibrations to reach the cradle system 100. Similarly, another vibration producing component HVAC compressor 40 (not shown) can also be mounted on the cradle 100 between brackets 12c, 12d and the vibrations produced thereon are isolated by means of rubber bushes disposed in-between the cradle 100 and HVAC compressor 40 to stop the vibrations of HVAC compressor 40 to reach the cradle system 100. Brackets 5a, 5b and 5c, 5d (not visible here) are for mounting the TCU 90 thereon from top, and brackets 6a, 6b, 6c, 6d are for mounting the OBC charger 30 thereon from top of the vehicle. The brackets 6a, 6b are welded on the front and rear members 1a, 1b of the base frame BF and brackets 6c, 6d are welded on the left-side and right-side members 2a, 2b of the base frame (BF). The cradle system 100 mounted with all the drive components is assembled on the electric vehicle front end body from the bottom thereof. The complete cradle system 100 mounted with the above drive components is fastened to body siderails with the help of four brackets 13a, 13b, 13c, 13d.

Figure 4 shows the cradle system 100 configured in accordance with the present invention in the structural and positioning frame for mounting the electric powertrain and other drive components thereon. It includes the connections between various components and/or sub-assemblies thereof. Here, the BIW is shown in the background in lighter shade. The cradle system 100 includes another high-voltage cable 112 leads from the outboard charger 30. A DC-DC Converter 10 is charged through a high-voltage cable 114. The power distribution unit (PDU) 20 is connected via a DC 72 V cable 22 to HVAC compressor 40. The HVAC compressor 40 is connected via another cable 42 to outboard charger (OBC) 30. A low-voltage wiring harness 104 has several lines leading to it from different components of EPT, e.g. DC-DC Converter 10; chiller unit 50; water pumps 70, 80; of electric powertrain (EPT) 60. The water pumps 70, 80 supply water for cooling via respective outlet pipes 72, 82. The telematics control unit (TCU) 90 is connected via a high-voltage cable 92 to outboard charger (OBC) 30.

Figure 5 shows a partially exploded view of encircled detail “A” of the cradle system 100 configured in accordance with the present invention and as shown in Figure 3a, which is mounted without the EPT drive components thereon. The cradle system 100 is made up of a plurality of subcomponents shown herein, e.g. the vertical members 102 thereof are having different heights according to the required mounting position of DC-DC Converter 10, PDU 20, TCU 90, and water pump 80. A horizontally placed profiled member 16 is fitted by means of fasteners 18 (in the direction of blue arrows 15) on top of the vertical members 102 therebetween on the LHS in Figure 3a and another bracket 12 is fitted by means of fasteners 19 tightened laterally (in the direction of blue arrows 17) from the side thereof on another vertical member 102 in the middle, for combinedly supporting the DC-DC Converter 10 on top of thereon of the cradle system 100. The cradle system 100 also includes at the base 120 thereof, a plurality of upwardly inclined projected seats 24 for supporting the TCU 90 as well as OBC 30 (Figure 3a) thereon. Similarly, a pair of horizontal members 22 are provided on the RHS of the cradle system 100 attached to a respective pair of vertical members 102 on the cradle system base 120 for supporting the PDU 20 thereon. In order to avoid the difficult task of welding of profiled members 8 and 9 for the assembly of TCU 90, profiled members 8 and 9 are bolted to vertical members 7a-7b and 7c (Figure 4) for supporting the DC-DC converter 10 for easily assembling the TCU 90 thereon. Another bracket 10 is provided for mounting of chiller unit 50 and brackets 12a and 12b are provided for mounting of water pumps 70, 80 thereon. The cradle system 100 mounted with all the drive components is assembled on the electric vehicle front end body from the bottom thereof. The complete cradle system 100 mounted with the above drive components is fastened to body siderails with the help of four brackets 13a, 13b, 13c, 13d.

In this way, the unique configuration of the cradle system 100 configured in accordance with the present invention facilitates to install different components/subassemblies connected through various electric cables and/or pipes to the electric powertrain (EPT) 60 in a multi-stage structure to accommodate the whole EPT drive unit within the limited installation space inside the BIW and without requiring any additional cradle for mounting the DC-DC converter 10 and PDU 20, which would have been required in a conventional arrangement. Moreover, all structural elements of this structural and positioning frame is composed of tubular construction made of cylindrical or square tubes, thereby this unique, multi-stage cradle structure substantially reduces the overall weight of this unique cradle system 100 configured for mounting the electric powertrain (EPT) 60 and other drive components thereof, e.g. DC-DC Converter 10, PDU 20, OBC 30, HVAC Compressor 40, Chiller Unit 50, Water Pumps 70, 80, and TCU 90 of the electric vehicle. Finally, the placement and mounting of heavier units like HVAC Compressor 40 and electric powertrain (EPT) 60 from below the cradle system 100 and rest of the comparatively lighter ETP components like DC-DC Converter 10, PDU 20, OBC 30, HVAC Compressor 40, Chiller Unit 50, Water Pumps 70, 80, and TCU 90 from above and on top of this cradle system 100 makes the installation as well as the dismantling thereof easier and less time-consuming for assembly and/or replacement/repairs thereof. It is also to be noted that the heights of the vertical members 7a, 7b, 7c, 7d, 7e, 7f, 7g, and the lengths of the horizontal cross-members 7i, 7h, are optimized to accommodate the electric powertrain EPT 60 and other drive components such as DC-DC Converter 10, Power Distribution Unit (PDU) 20, Outboard Charger (OBC) 30, HVAC Compressor 40, Chiller Unit 50, Water Pumps 70, 80, Telematics Control Unit (TCU) 90 of the EPT 60 within the existing space available inside the BIW.
TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The cradle system with a tubular structural and positioning frame for mounting electric powertrain of an electric vehicle, configured in accordance with the present invention offers the following advantages:

• Single cradle assembly supports almost all electric drive components.

• Eliminates an additional cradle for mounting PDU & DC-DC converter.

• Offers optimized weight with reduced cost using tubular cross-sections.

• Reduces welding due to increased use of tubular cross-sections.

• Retains material properties of tubular cross-sections with a reduced weight than the convention C-in-C section .

• Single assembly of various tubular members/subcomponents used in this cradle system also reduce the welding therein as compared to the C-in-C section used in the conventional structure thereof.

• Ease of assembly, repair and/or replacement of components on/from this cradle system due to divided and multi-staged placement of parts from the top/bottom thereof.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

Terms concerning attachments, coupling and the like, such as “connected” and “interconnected”, refer to a relationship, wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. , Claims:We claim:

1. A cradle system (100) for mounting an electric powertrain (EPT) of an electric vehicle, comprising: a lightweight tubular structural and a positioning frame thereof for ease of assembly, repair and/or replacement of said electric powertrain (EPT) (60) and other drive components thereof, wherein said electric powertrain (EPT) (60) and other drive components such as a DC-DC Converter (10), a Power Distribution Unit (PDU) (20), an Outboard Charger (OBC) (30), a HVAC Compressor (40), Chiller Unit (50), Water Pumps (70, 80), a Telematics Control Unit (TCU) (90) and/or the corresponding electrical cable/s and/or hydraulic lines therebetween, are all disposed in a multi-stage structure from the top and/or under the base of said cradle structure for ease of assembly, repair and/or replacement of said EPT (60) and DC-DC Converter (10), PDU (20), OBC (30), HVAC Compressor (40), Chiller Unit (50), Water Pumps (70, 80), and TCU (90) and the like.

2. The cradle system (100) as claimed in claim 1, wherein the structural and positioning frame of said cradle system (100) comprises:

• a base frame (BF) having front and rear members (1a, 1b) of circular cross-sections and left-side and right-side members (2a, 2b) of C-in-C sections, as well as two middle members of tubular cross-sections, forming a lightweight tubular structure;

• a plurality of vertical members (7a, 7b, 7c) fitted with a bracket (8) and a tubular member (9) to support said DC-DC Converter (10) thereon;

• a plurality of vertical members (7d, 7e, 7f, 7g) of same height and horizontal cross-members (7i, 7h) to support said PDU (20) thereon;

• a pair of brackets (6a, 6b) welded on said front and rear members (1a, 1b) of said base frame (BF), and another pair of brackets (6c, 6d) welded on said left-side and right-side members (2a, 2b);

• a bracket (12d) welded on said front member (1a) to support said HVAC compressor (40) thereon;

• a bracket (12c) welded on said front member (1a) to mount said chiller unit (50) thereon;

• a plurality of brackets (4a, 4b, 4c) welded to said base frame (BF) to support said EPT (60) thereon;

• and a pair of brackets (12a, 12b) to mount water pumps (70, 80) thereon; and

• a plurality of brackets (4a, 4b, 4c) to support said TCU (90) thereon;

wherein said cradle system (100) is isolated from motor vibrations generated in said electric powertrain (EPT) (60) by the rubber mounts (200), and from the vibrations generated in said HVAC compressor (40) by the rubber bushes.

3. The cradle system (100) as claimed in claim 2, said cradle system (100) is mounted along with the drive components such as DC-DC Converter (10), Power Distribution Unit (PDU) (20), Outboard Charger (OBC) (30), HVAC Compressor (40), Chiller Unit (50), Water Pumps (70, 80), Telematics Control Unit (TCU) (90), and said EPT (60), by fastening said cradle system (100) within the body-in-white (BIW) by four brackets (13a, 13b, 13c, 13d) welded on said left-side and right-side members (2a, 2b).

4. The cradle system (100) as claimed in claim 3, said EPT (60) is mounted from under the base frame (BF) of said cradle system (100) and supported on said brackets (4a, 4b, 4c) welded to said base frame (BF).

5. The cradle system (100) as claimed in claim 3, wherein said rubber mounts (200) are disposed on said brackets (4a, 4b, 4c) and mounted between said electric powertrain EPT (60) and cradle system (100) to prevent the motor vibrations from reaching said cradle system (100).

6. The cradle system (100) as claimed in claim 2, wherein said rubber bushes are disposed between said HVAC Compressor (40) and cradle system (100) to prevent the vibrations of said HVAC compressor (40) from reaching said cradle system (100).

7. The cradle system (100) as claimed in claim 2, wherein said bracket (8) is a detachable bracket configured substantially triangular and fastened on said vertical member (7d) by means of a plurality of fasteners (17, 18).

8. The cradle system (100) as claimed in claim 2, wherein said tubular member (9) is a detachable member profiled to connect said vertical members (7a, 7b) tightened on top thereof by means of a pair of fasteners (18).

9. The cradle system (100) as claimed in claim 2, wherein said base frame (BF) comprises a front and rear cylindrical longitudinal member (1a, 1b) each, two cylindrical middle members (3, 14) as well as two cross-members (2a, 2b) of C-in-C sections respectively.

10. The cradle system (100) as claimed in claim 2, wherein said vertical members (7a, 7b) are configured with the same height and said vertical member (7c) is made smaller than said vertical members (7a, 7b) to be fitted with the rear end of said profiled tubular member (9) thereon and the front end thereof fitted on said vertical members (7a, 7b) to combinedly support said DC-DC Converter (10) thereon.

11. The cradle system (100) as claimed in claim 10, wherein said profiled tubular member (9) comprises a pair of mounting brackets (9a, 9b) welded on top thereof and another pair of mounting brackets (9c, 9d) laterally welded on the inner side of said tubular member (9) to support said DC-DC Converter (10) thereon.

12. The cradle system (100) as claimed in claim 10, wherein a pair of seats (20a, 20b) are welded on said cross-member (7i) and another pair of perforated washers (20c, 20d) are welded on said cross-member (7h) for fastening said PDU (20) supported on said cross-members (7i, 7h).

13. The cradle system (100) as claimed in claim 4, wherein said rubber mounts (200) are disposed between said brackets (4a, 4b, 4c) and electric powertrain EPT (60) for isolating the motor vibrations generated therein from reaching said cradle system (100).

14. The cradle system (100) as claimed in claim 2, wherein said rubber bushes are disposed between said bracket (12d) and compressor (40) for isolating vibrations generated therein from reaching said cradle system (100).

15. The cradle system (100) as claimed in claim 2, wherein said brackets (13a, 13b, 13c, 13d) are welded outside said side members (2a, 2b) of said base frame (BF) for fastening of said cradle system (100) along with said electric powertrain EPT (60) and other drive components accommodated within the siderails of said BIW from the bottom-side thereof.

16. The cradle system (100) as claimed in claim 2, wherein the heights of said vertical members (7a, 7b, 7c, 7d, 7e, 7f, 7g) and the lengths of said horizontal cross-members (7i, 7h) is optimized to accommodate said electric powertrain (EPT) (60) and other drive components such as DC-DC Converter (10), Power Distribution Unit (PDU) (20), Outboard Charger (OBC) (30), HVAC Compressor (40), Chiller Unit (50), Water Pumps (70, 80), Telematics Control Unit (TCU) (90) of said EPT (60) within the existing space available inside said BIW.

Dated this 02nd day of August 2023.

Digitally / e-Signed by:

(SANJAY KESHARWANI)
APPLICANT’S PATENT AGENT
REGN. NO. IN/PA-2043.