DESC:POWERTRAIN MOUNTING FOR A VEHICLE
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202421002169 filed on 11/01/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to a powertrain mounting arrangement for a saddle type vehicle. Particularly, the present disclosure relates to a stacked mounting of powerpack and transmission unit in a dual cradle frame of a saddle type of vehicle.
BACKGROUND
The automotive industry has long been driven by the need to meet consumer demands for more affordable, efficient, and high-performing vehicles. One area of significant innovation is the mounting of critical components such as the powerpack and transmission unit. Consequently, the automotive industry has continuously sought to optimize the mounting mechanism for heavy components of the vehicle for improved performance, reduced weight, and cost efficiency.
Conventionally, the heavy components such as a battery pack, motor, and transmission unit of the vehicle are mounted in a layered manner requiring a larger and continuous frame. The components are arranged vertically or horizontally in a stacked formation within a single, integrated vehicle frame. Further, the components are rested directly adjacent to each other and are directly fastened to the vehicle frame. The components are strategically positioned to optimize vehicle efficiency by ensuring that the components are placed in a balanced and space-efficient manner.
However, there are certain problems associated with the existing or above-mentioned mounting mechanism of the powertrain for a saddle type vehicle. For instance, direct mounting of the vehicle components onto the vehicle frame presents several challenges related to structural integrity and component performance. Specifically, the direct contact between components and vehicle frame leads to increased vibrations and shocks which are transferred to sensitive parts, such as the battery or motor. Consequently, the lack of vibration isolation negatively impacts the longevity and efficiency of the components, as the constant vibrations may cause internal damage, loosening of mounts, or overheating in critical areas. Additionally, the direct mounting onto the vehicle frame further complicates the maintenance and repair process. Since the components are directly affixed to the cradle tubes without intermediary structures, any need for adjustments or replacements requires the disassembly of the entire system resulting in a labour-intensive and time-consuming repairing process.
Therefore, there exists a need of a mounting mechanism of the powertrain for a saddle type vehicle that is efficient, safe, and overcomes one or more problems as mentioned above.
SUMMARY
An object of the present disclosure is to provide a powertrain mounting arrangement for a saddle type vehicle.
Another object of the present disclosure is to provide a dual frame for a saddle type vehicle comprising a lower cradle and an upper cradle for enhanced structural stability for powertrain mounting.
In accordance with an aspect of the present disclosure, there is provided a powertrain mounting arrangement for a saddle type vehicle, the powertrain mounting arrangement comprises:
- a vehicle frame comprising a plurality of frame tubes elongated between a head tube, and a bottom tube, to form a cradle;
- at least one powerpack;
- a transmission unit; and
- an electric motor,
wherein the vehicle frame comprises a plurality of cradle tubes configured to divide the cradle into an upper cradle and a lower cradle, and wherein the upper cradle is configured to accommodate the at least one powerpack and the lower cradle configured to accommodate the transmission unit and the electric motor.
The powertrain mounting arrangement for a saddle type vehicle, as described in the present disclosure, is advantageous in terms of providing a powertrain mounting with enhanced stability and durability. The inclusion of a resting bracket enhances structural stability and support for critical components such as the battery or motor. Further, the resting bracket between cradle tubes secures the mounted components in place, preventing the movement or vibrations and thereby enhancing the vehicle performance and safety.
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 illustrates a exploded view of a powertrain mounting arrangement for a saddle type vehicle, in accordance with an embodiment 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 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 recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the term “powertrain” refers to a comprehensive unit that includes all components for generating, managing, and delivering electrical power for the movement of the electric vehicle. The powertrain assembly comprises an electric motor, a battery pack, a transmission unit, and power electronics circuitry. Further, the electric motor converts electrical energy from the battery into mechanical energy. Subsequently, the battery pack stores the mechanical energy, and the transmission unit transfers power to the wheels. Further, the power electronics circuitry controls energy flow, including inverters that convert direct current to alternate current. Additionally, many electric vehicles feature regenerative braking systems that capture kinetic energy during braking to recharge the battery. Overall, the powertrain assembly ensures efficient performance, responsiveness, and optimal energy management for the electric vehicle.
As used herein, the terms “saddle type vehicle”, and “vehicle” are used interchangeably and refer to a vehicle designed with a seating configuration for the rider to sit on a seat or saddle. In saddle vehicles, the rider legs are positioned on either side of the seat, providing stability and control while riding. The saddle serves as the primary point of contact between the rider and the vehicle, with the rider using their body weight and balance to steer and control the vehicle. The saddle type design is common in bicycles, motorcycles, and electric bikes as the saddle provides comfort, support, and freedom of movement during riding. The saddle type design may include bicycles, motorcycles, and electric bikes, where the saddle provides comfort, support, and freedom of movement during riding.
As used herein, the terms “vehicle frame”, “frame”, and “chassis” are used interchangeably and refer to a structural component that provides the foundation for all other parts of the vehicle, including the motor, battery pack, wheels, suspension, and body. Further, the frame is designed to support the electric powertrain involving higher torque and weight distribution considerations compared to traditional internal combustion engine (ICE) vehicles. The frames are constructed from materials such as (but not limited to) aluminium, steel, or composite materials to achieve a balance between strength, rigidity, and overall weight reduction. Furthermore, the frame also incorporates crumple zones to absorb impact energy in the event of a collision, enhancing the rider safety.
As used herein, the term “frame tube” refers to the structural component that forms the main skeleton or framework of the vehicle. The frame tubes are designed to support the weight of the vehicle and its components as the frame tube provides strength and stability to the overall structure. The design of the frame tubes ensures that the frame efficiently absorbs forces during movement, such as impacts, vibrations, and road stresses, ensuring a safe and durable structure for the vehicle. The frame tubes form the skeletal structure of the vehicle, providing support, and rigidity and distributing the weight and forces experienced during operation. The frame tube acts as a foundation for attaching critical components of the vehicle such as the transmission unit, motor, suspension system, and body panels. The design of the frame tubes, including the placement and configuration of the tubes influence the vehicle ability to absorb shocks and impact. In modern automotive design, the frame tubes are part of a unibody or ladder frame design, with manufacturers optimizing their shape and material for weight savings, cost efficiency, and performance.
As used herein, the term “head tube” refers to a cylindrical part of a vehicle that connects the front fork to the vehicle frame and assists in the smooth movement of the front fork to enable steering. The primary function of the head tube is to provide structural support to the front fork and ensure proper alignment with the handlebars. The design and dimensions of the head tube play an important factor in the overall handling, stability, and manoeuvrability of the vehicle, as it directly affects the steering system interaction with the rest of the vehicle frame.
As used herein, the term “bottom tube” refers to a cylindrical structural component that runs along the lower section of the frame, connecting the front and rear parts of the vehicle frame. The bottom tube serves as a critical load-bearing element that provides strength and stability to the overall vehicle frame. The bottom tube is located at the base of the vehicle frame and distributes force and stress that the vehicle experiences during use, such as those from the suspension, and road or terrain irregularities. The bottom tube plays a significant role in maintaining alignment and preventing flexing in the frame. In addition to its structural function, it also contributes to the overall rigidity of the vehicle, which affects the handling, stability, and safety of the vehicle.
As used herein, the term “cradle” refers to the frame structure that supports and secures key components, such as the battery and motor, ensuring the components are firmly positioned and protected during operation. The cradle is an essential part of the vehicle frame design, as it helps to distribute the weight of the battery and motor evenly to maintain balance and stability. The cradle is integrated into the frame and is designed to accommodate the specific shape and size of the vehicle power system. The primary function of the cradle is to reduce vibrations, protect delicate components, and contribute to the overall durability and longevity of the electric bike.
As used herein, the term “powerpack” refers to an assembled unit of a plurality of cell arrays that are connected electrically to form a larger energy storage capable of delivering the required amount of energy for high-power applications. The battery modules may be arranged in series or parallel configurations depending on the desired voltage and capacity requirements. The battery modules of the powerpack connected in series increase the overall voltage of the energy storage system. The electrical connections in the powerpack are formed by connecting the terminals of the battery cells with bus bars. Furthermore, in addition to the individual cells, a powerpack also includes circuitry for balancing the charge levels of the cells, managing the charging and discharging processes, and providing safety features such as overcharge and over-discharge protection. The powerpack, along with the associated electronics and packaging, forms the core component of an energy storage system, enabling the efficient and reliable storage and delivery of electrical energy.
As used herein, the term “transmission unit” refers to a component of an electric vehicle that manages the transfer of power from the electric motor to the wheels. Many EVs incorporate a single-speed transmission that allows the electric motor to deliver consistent torque and power across a wide range of speeds. Further, the transmission unit facilitates energy efficiency optimization and boosts overall vehicle performance. Additionally, some advanced EVs may employ a multi-speed transmission to further improve responsiveness and adaptability to different driving conditions. Overall, the transmission unit is essential for ensuring a smooth driving experience, maximizing the electric motor capabilities, and contributing to the vehicle's overall efficiency and performance.
As used herein, the terms “electric motor” and “motor” are used interchangeably and refer to any device or a machine that uses electrical energy to produce rotating motion or mechanical energy. The motor consists of a stator and a rotor. The flow of electrical current through the motor generates a magnetic field that turns the rotor, producing a mechanical movement. Various types of motors may include (but not limited to) DC shunt motors, DC series motors, AC induction motors, AC synchronous motors, and switched reluctance motors.
As used herein, the term “cradle tubes” refers to the structural tubes within the vehicle frame that divide the cradle to accommodate the components such as the battery, motor, and transmission unit. The cradle tubes are part of the frame overall design and are strategically placed to ensure that the heavy components are securely mounted to ensure the vehicle stability and balance. Further, the cradle tubes distribute the weight of the mounted components evenly thereby preventing the vehicle from imbalance during the ride.
As used herein, the term “resting bracket” refers to a structural component designed to support and secure the power pack in a cradle structure. The resting bracket provides a stable platform for the power pack to rest securely, preventing it from shifting or being damaged. The design of a resting bracket is modified to the specific dimensions and weight of the powerpack, often made from durable materials such as, but not limited to, aluminium or reinforced plastic. The resting bracket is mounted into the frame or attached to it using bolts or clamps. Additionally, the resting brackets reduce wear on the powerpack by providing consistent support, ensuring that the powerpack electrical contacts remain secure.
As used herein, the term “powerpack support bracket” refers to a securing component designed to attach the powerpack to the vehicle frame in the specified position. The powerpack support brackets ensure that the battery remains firmly in place during riding, preventing unwanted movement that may affect the vehicle balance, stability, or performance. The powerpack support brackets are designed to withstand the stresses and vibrations encountered during riding and to provide easy access for battery removal and installation. Further, precise placement of the powerpack support brackets enables the distribution of the battery weight evenly across the frame, contributing to the vehicle overall handling and performance.
As used herein, the term “unibody structure” refers to a frame designed from a single, continuous piece to house a number of vehicle components together. The unibody structure eliminates the need for additional joints or fasteners, providing an efficient construction that enhances the vehicle strength and rigidity. the unibody structure allows for better weight distribution, as the battery, motor, and other components are often integrated into the frame, creating a seamless look and reducing the overall weight of the vehicle.
As used herein, the term “support brackets” refers to a component designed to provide support and secure various parts of the vehicle to the vehicle frame. The support brackets provide structural stability to the vehicle by firmly holding the mounted parts in place, ensuring that they remain secure during riding. Further, the support brackets are made from materials such as, but not limited to, aluminium, steel, or high-strength plastic to withstand the stresses during the vehicle ride through rough conditions.
In accordance with an aspect of the present disclosure, there is provided a powertrain mounting arrangement for a saddle type vehicle, the powertrain mounting arrangement comprises:
- a vehicle frame comprising a plurality of frame tubes elongated between a head tube, and a bottom tube, to form a cradle;
- at least one powerpack;
- a transmission unit; and
- an electric motor,
wherein the vehicle frame comprises a plurality of cradle tubes configured to divide the cradle into an upper cradle and a lower cradle, and wherein the upper cradle is configured to accommodate the at least one powerpack and the lower cradle configured to accommodate the transmission unit and the electric motor.
Referring to figure 1, in accordance with an embodiment, there is described a powertrain mounting arrangement 100 for a saddle type vehicle. The powertrain mounting arrangement 100 comprises a vehicle frame 102 comprising a plurality of frame tubes 104 elongated between a head tube 106, and a bottom tube 108, to form a cradle, at least one powerpack 110, a transmission unit 112, and an electric motor 114. Further, the vehicle frame 102 comprises a plurality of cradle tubes 116 configured to divide the cradle into an upper cradle 118 and a lower cradle 120, and wherein the upper cradle 118 is configured to accommodate the at least one powerpack 110 and the lower cradle 118 configured to accommodate the transmission unit 112 and the electric motor 114. Furthermore, the vehicle frame 102 comprises at least one resting bracket 122 mounted between the plurality of cradle tubes 116. Furthermore, the powertrain mounting arrangement 100 comprises a plurality of powerpack support brackets 124 configured to secure the at least one powerpack 110 in the upper cradle 118. Furthermore, the transmission unit 112 and the electric motor 114 are integrated as a unibody structure 126. Furthermore, the powertrain mounting arrangement 100 comprises a plurality of support brackets 128A, 128B, and 128C configured to secure the unibody structure 126 within the lower cradle 120.
The division of the vehicle frame into an upper cradle 118 and lower cradle 120 via a plurality of cradle tubes 116 ensures optimal weight distribution, allowing for more balanced handling and stability of the vehicle. The upper cradle 118 accommodates the powerpack 110, which consists of the vehicle battery system, and the lower cradle 120 is dedicated to the transmission unit 112 and electric motor 114. The separation of components minimizes interference between high-torque elements (electric motor 114 and transmission unit 112) and the powerpack, enhancing performance and reducing the risk of damage to sensitive components. Furthermore, the elongated frame tube 104 between the head tube 106 and bottom tube 108 creates a robust, integrated structure that withstands dynamic loads during operation, ensuring greater durability and longevity. The separation of components into distinct upper 118 and lower cradles 120 also aids in simplifying the assembly and maintenance processes. Consequently, each cradle section is accessed and serviced independently, making repairs or upgrades more efficient.
In an embodiment, the vehicle frame 102 comprises at least one resting bracket 122 mounted between the plurality of cradle tubes 116. The inclusion of a resting bracket 122 enhances structural stability and support for critical components such as the battery or motor. Further, the positioning of the resting bracket 122 between cradle tubes 116 secures the mounted components in place, preventing the movement or vibrations that affect the vehicle performance and safety. Furthermore, the resting bracket 122 acts as a secure mounting platform, ensuring that the weight of the components is distributed evenly across the vehicle frame 102 and thereby contributes to better handling and overall balance. Additionally. the resting bracket 122 mounted between the cradle tubes 116, ensures that the components are held securely without requiring additional external supports or fasteners, reducing the overall weight of the vehicle and thereby improving the vehicle efficiency and performance.
In an embodiment, the at least one resting bracket 122 is configured to provide a resting platform to the at least one powerpack 110. Beneficially, a dedicated resting platform for the at least one powerpack 110 ensures that the powerpack 110 is securely held in place during the vehicle operation. Consequently, the risk of the powerpack 110 shifting and/or misaligned is reduced thereby, enhancing the vehicle performance, efficiency, and safety. Further, the resting bracket 122 protects the powerpack 110 from the damage caused by vibrations or shocks during riding, as the resting bracket 122 absorbs and distributes the forces arising from the vibrations. Additionally, a fixed resting platform ensures that the powerpack remains properly aligned and thereby minimizes the wear on the connectors or electrical terminals.
In an embodiment, the powertrain mounting arrangement 100 comprises a plurality of powerpack support brackets 124 configured to secure the at least one powerpack 110 in the upper cradle 118. Advantageously, the support across multiple brackets ensures that the powerpack 110 is securely mounted, preventing any unwanted movement or shifting in the upper cradle 118. Further. the use of several brackets allows for a more even distribution of the powerpack weight within the upper cradle 118, thereby maintaining a balanced center of gravity and enhanced ride quality. Furthermore, the powerpack support brackets 124 mounting arrangement facilitates ease of maintenance, as the powerpack 110 is quickly accessed for removal or replacement, without requiring complex disassembly.
In an embodiment, the plurality of powerpack support brackets 124 are removably connected to the vehicle frame 102. The powerpack support brackets 124 being removably connected to the vehicle frame 102 provide greater flexibility and convenience for maintenance, repair, and component upgrades. The removable support brackets 124 allow for easy detachment of the powerpack 110, facilitating simple access to the battery for charging, maintenance, or replacement. Consequently, the time and effort required for servicing are significantly reduced, as components are removed quickly or replaced without the need for extensive disassembly of the frame. Additionally, the ability to remove the support brackets 124 ensures that the powerpack 110 is safely stored or transported separately from the vehicle, reducing the risk of damage during handling. Further, the removable nature of the powerpack 110 support brackets 124 enhances the customization and compatibility with different powerpack 110 configurations or upgrades.
In an embodiment, the transmission unit 112 and the electric motor 114 are integrated as a unibody structure 126. Advantageously, the integration of the transmission unit 112 and electric motor 114 as a unibody structure 126 reduces the complexity of the vehicle powertrain. Consequently, the above-mentioned integration minimizes the number of connections and moving parts between motor 114 and transmission unit 112, thereby improving power transfer efficiency and the potential for mechanical failure. The unibody structure 126 ensures that the transmission and motor 114 work in coordination, optimizing performance by reducing energy losses due to misalignment or friction between separate components. Further, the compact integrated structure contributes to weight reduction, as the need for extra brackets or mounting points is eliminated thereby, improving the overall weight distribution and handling of the vehicle.
In an embodiment, the unibody structure 126 is formed via a common housing. The unibody structure 126 formed via a common housing provides a single, unified enclosure that eliminates the need for separate casings or mounting structures. Consequently, the overall structure is simplified and reduces the number of parts involved in securing the unibody structure 126. The unibody structure 126 also results in fewer points of potential failure, as the risks associated with loose connections, misalignments, or complex junctions are minimized, leading to improved operational reliability. From an advantages perspective, the use of a common housing for the unibody structure 126 improves the strength and durability of the entire system. The seamless design provides additional protection to internal components from external elements like dust, dirt, moisture, and impacts, helping extend the lifespan of the electric bike's drivetrain.
In an embodiment, the powertrain mounting arrangement 100 comprises a plurality of support brackets 128 configured to secure the unibody structure 126 within the lower cradle 120. The support brackets 128A, 128B, and 128C effectively hold the unibody structure 126 that houses the integrated motor 114 and transmission unit 112, firmly in place within the vehicle frame 102. Further, the multiple support brackets 128A, 128B, and 128C distribute the load and stress exerted on the powertrain evenly, minimizing the risk of damage or misalignment. Consequently, the unibody structure 126 remains securely mounted during high-torque or off-road riding conditions, contributing to smoother operation and improved safety. Further, the servicing or replacing of the powertrain becomes easier, as the multiple support brackets 128A, 128B, and 128C allow for quicker removal and installation of the unibody structure 126.
In an embodiment, the unibody structure 126 is secured removably within the lower cradle 120, via the plurality of support brackets 128. Beneficially, securing the unibody structure 126 removably within the lower cradle 120 provides flexibility and ease of maintenance for the powertrain system. Further, the removable unibody structure 126 allows for quick and efficient access to the motor 114 and transmission unit 112 for servicing, repairs, or upgrades. Specifically, the replacement of any part within the powertrain or the entire unibody structure 126 is easily performed without the need for extensive disassembly of the frame. Furthermore, the use of support brackets 128 to secure the unibody structure 126 ensures that the powertrain remains stable and securely mounted when in place, preventing unwanted vibrations or misalignment.
Based on the above-mentioned embodiments, the present disclosure provides significant advantages such as (but not limited to) enhances structural stability and support for critical components, preventing the movement or vibrations that affect the vehicle performance and safety, and therefore, improving the vehicle efficiency and performance.
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.
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. A powertrain mounting arrangement (100) for a saddle type vehicle, the powertrain mounting arrangement (100) comprises:
- a vehicle frame (102) comprising a plurality of frame tubes (104) elongated between a head tube (106), and a bottom tube (108), to form a cradle;
- at least one powerpack (110);
- a transmission unit (112); and
- an electric motor (114),
wherein the vehicle frame (102) comprises a plurality of cradle tubes (116) configured to divide the cradle into an upper cradle (118) and a lower cradle (120), and wherein the upper cradle (118) is configured to accommodate the at least one powerpack (110) and the lower cradle (120) configured to accommodate the transmission unit (112) and the electric motor (114).

2. The powertrain mounting arrangement (100) as claimed in claim 1, wherein the vehicle frame (102) comprises at least one resting bracket (122) mounted between the plurality of cradle tubes (116).

3. The powertrain mounting arrangement (100) as claimed in claim 2, wherein the at least one resting bracket (122) is configured to provide a resting platform to the at least one powerpack (110).

4. The powertrain mounting arrangement (100) as claimed in claim 1, wherein the powertrain mounting arrangement (100) comprises a plurality of powerpack support brackets (124) configured to secure the at least one powerpack (110) in the upper cradle (118).

5. The powertrain mounting arrangement (100) as claimed in claim 1, wherein the plurality of powerpack support brackets (124) are removably connected to the vehicle frame (102).

6. The powertrain mounting arrangement (100) as claimed in claim 1, wherein the transmission unit (112) and the electric motor (114) are integrated as a unibody structure (126).

7. The powertrain mounting arrangement (100) as claimed in claim 6, wherein the unibody structure (126) is formed via a common housing.

8. The powertrain mounting arrangement (100) as claimed in claim 1, wherein the powertrain mounting arrangement (100) comprises a plurality of support brackets (128) configured to secure the unibody structure (126) within the lower cradle (120).

9. The powertrain mounting arrangement (100) as claimed in claim 8, wherein the unibody structure (126) is secured removably within the lower cradle (120), via the plurality of support brackets (128).