Description:FORM 2

THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

A COVER ASSEMBLY FOR AN ELECTRIC MACHINE

APPLICANT:

TVS MOTOR COMPANY LIMITED, (an Indian Company)

at: “Chaitanya”, No. 12, Khader Nawaz Khan Road, Nungambakkam, Chennai – 600034, Tamil Nadu, India.

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
[0001] The present invention relates to a cover assembly for an electric machine and more specifically, but not exclusively, to a cover assembly for an electric machine of a vehicle.

BACKGROUND
[0002] In an electric vehicle, during the operations of electric hub motors (hereinafter referred to as ‘motor’), heat is generated due to losses such as power loss, eddy current loss, hysteresis loss etc. This is particularly true for motors such as IP67-rated motors which are sealed from inside thereby restricting axial airflow. This generated heat affects the performance and durability of the motor. Further, to increase the performance, the current supply to the motor cannot be increased due to the factors like amount of heat generated, lack of cooling, and current carrying capacity of the conductors of the motor. Additionally, existing cooling solutions for motors, specifically for the electric hub motors are often ineffective, especially in high-performance applications and in enclosed configurations. This is because the existing solutions typically rely on passive convection cooling through a cover of the electric hub motors, which is not sufficient to dissipate the amount of heat generated during the operations. As a result, the motor can overheat, leading to reduced performance and lifespan.
[0003] The existing cover of the motor may include projections or fins-like structures on the outer surface to increase surface area for heat dissipation, but these structures are not very effective and affect the aesthetics of the wheel and vehicle performance due to air drag. Other cooling methods use a coolant or liquid for cooling the motor or its parts, but these cooling techniques require additional components, such as pumps, fluid channels etc. which make the configuration of the cooling assembly complex and increases the weight as well as cost of the vehicle. Additionally, some other solutions focus on axial airflow using external means such as fans. While this approach can be effective for cooling induction motors, it is not as effective for cooling the motors which are sealed closely from the inside, which restricts the axial airflow. Additionally, the active cooling systems including fans and pumps need additional power supply which impacts the range of electric vehicles and further complicates the vehicle architecture.
[0004] Therefore, there is a need for a more effective cooling solution for electric motors, especially those used in electric vehicles.

SUMMARY OF THE INVENTION
[0005] The present invention relates to a cover assembly for an electric machine. The cover assembly comprises one or more primary cover members and one or more secondary cover members. The one or more primary cover members are configured to enclose the electric machine and the one or more primary cover members are configured to receive a shaft member of the electric machine through an opening. The one or more primary cover members configured to rotate freely on the shaft member. The one or more secondary cover members are configured with the one or more primary cover members. The one or more secondary cover members are configured to maintain a gap between one or more primary cover members and the one or more secondary cover members. The cover assembly also includes a plurality of projections which are disposed in the gap between the one or more primary cover members and the one or more secondary cover members.
[0006] The present invention also relates to an electric machine for a wheel assembly of a vehicle. The electric machine comprises a rotating member and a shaft member. The rotating member is configured to rotate integrally with rotor ring of the electric machine. The shaft member is configured to mount a cover assembly.
The cover assembly comprises one or more primary cover members and one or more secondary cover members. The one or more primary cover members are configured to enclose the electric machine. The one or more primary cover members are configured to rotate freely on the shaft member. The one or more secondary cover members are configured with the one or more primary cover members. The one or more secondary cover members are configured to maintain a gap between one or more primary cover members and one or more secondary cover members. The plurality of projections is disposed in the gap between the one or more primary cover members and the one or more secondary cover members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The proposed invention is described with reference to an exemplary embodiment of a cover assembly for an electric machine of a vehicle. The same reference numerals are used throughout the drawings to reference similar features and components. Description of certain details and implementations follow, including a description below, as well as a discussion of other potential embodiments described below, as well as a discussion of other potential embodiments or implementations of the inventive concepts provided below, followed by a more detailed description with reference to the drawings.
[0008] Figure 1: illustrates an inside perspective view of a left primary cover member of one or more primary cover members along with a plurality of projections as per one embodiment of the present disclosure.
[0009] Figure 2: illustrates a side perspective view of a left secondary cover member of one or more secondary cover members as per another embodiment of the present disclosure.
[0010] Figure 3: illustrates an inside perspective view of a left secondary cover member of one or more secondary cover members connected to a left primary cover member of one or more primary cover members as per another embodiment of the present disclosure.
[0011] Figure 4: illustrates an outside perspective view of a left primary cover member of one or more primary cover members as per another embodiment of the present disclosure.
[0012] Figure 5: illustrates a rear view of a left primary cover member of one or more primary cover members as per another embodiment of the present disclosure.
[0013] Figure 6: illustrates an outside perspective view of a right primary cover member of one or more primary cover members as per another embodiment of the present disclosure.
[0014] Figure 7: illustrates an inside perspective view of a right primary cover member of one or more primary cover members along with a plurality of projections as per another embodiment of the present disclosure.
[0015] Figure 8: illustrates an exploded view of an assembled configuration of a right primary cover member of one or more primary cover members and a right secondary cover member of one or more secondary cover members along with a plurality of projections disposed therebetween as per another embodiment of the present disclosure.
[0016] Figure 9: illustrates an inside perspective view of an assembled configuration of a right primary cover member of one or more primary cover members with a right secondary cover member of one or more secondary cover members as per another embodiment of the present disclosure.
[0017] Figure 10: illustrates cut section view of a right primary cover member of one or more primary cover members as per another embodiment of the present disclosure.
[0018] Figure 11: illustrates an inside perspective view of a right secondary cover member having a plurality of projections as per another embodiment of the present disclosure.
[0019] Figure 12: illustrates an outside perspective view of a right secondary cover member having a plurality of projections as per another embodiment of the present disclosure.
[0020] Figure 13: illustrates an exploded view of an assembly of a right primary cover member of one or more primary cover members and a right secondary cover member of one or more secondary cover members having plurality of projections as per another embodiment of the present disclosure.
[0021] Figure 14: illustrates an inside perspective view of an assembled configuration of a right primary cover member of one or more primary cover members and a right secondary cover member of one or more secondary cover members with plurality of projections as per another embodiment of the present disclosure.
[0022] Figure 15: illustrates a left side perspective view of a cover assembly mounted on a wheel rim of a wheel assembly and a shaft of an electric machine as per another embodiment of the present disclosure.
[0023] Figure 16: illustrates a rear perspective view of a cover assembly mounted on a wheel rim of a wheel assembly and a shaft member of an electric machine as per another embodiment of the present disclosure.
[0024] Figure 17: illustrates a rear perspective view of a vehicle having an electric machine and a cover assembly as per another embodiment of the present disclosure.

DETAILED DESCRIPTION
[0025] While the present invention has been shown and described with reference to the foregoing preferred embodiments, it will be apparent to those skilled in the art that changes in form, connection, and detail may be made therein without departing from the scope of the invention.
[0026] This written description uses examples to provide details on the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
[0027] It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in light of the above disclosure.
[0028] In the following description, numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects.
[0029] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder. Further “front” and “rear”, and “left” and “right” referred to in the ensuing description of the illustrated embodiment refer to front and rear, and left and right directions as seen from a rear portion of the cover assembly on the vehicle and looking forward. However, it is contemplated that the disclosure in the present invention may be applied to any vehicle without defeating the scope of the present subject matter. Further, a skilled person would also appreciate that the present invention can be applied to non-vehicular applications wherein a sealed motor or electric machine is used with limited options for heat dissipation or cooling. The detailed explanation of the constitution of parts other than the present invention which constitutes an essential part has been omitted at suitable places.
[0030] In order to address the one or more of the above-mentioned problems, the present invention provides a cover assembly for an electric machine. The present invention also relates to an electric machine for a wheel assembly of a vehicle.
[0031] As per one embodiment of the present invention, a cover assembly for an electric machine is provided. In an embodiment of the present invention, the electric machine may be an electric motor. In another embodiment, the electric machine may be a hub mounted electric machine for a vehicle. However, the invention is not limited to vehicular applications only. The cover assembly comprises one or more primary cover members and one or more secondary cover members. In an embodiment the one or more primary cover members may be made from a group of heat conductive materials such as aluminium, this helps in better heat dissipation during the operations of the vehicle and provide a large area for convection to take place as the area of the one or more primary cover is approximately close to the area of the wheel rim of a wheel assembly. The one or more primary cover members are configured to enclose an electric machine and the one or more primary cover members are configured to receive a shaft member of the electric machine through an opening. The one or more secondary cover members are configured to enclose at least a portion of the electric machine. In an embodiment of the present invention the one or more secondary cover members may be made up of plastic, polymer and any lightweight material. This helps in keeping the weight of the cover assembly as low as possible. The one or more primary cover members comprise an enclosed portion. The enclosed portion is configured to cover the electric machine and provide a sealed enclosure. In an embodiment of the present invention the enclosed portion comprises a plurality of projections. The one or more primary cover members configured to rotate freely on the shaft member. Therefore, when the one or more primary covers will be moving, the plurality of projections will start directing an airflow to cool down the electric machine. For example, during the operations of the electric machine, the one or more primary covers starts rotating on the shaft member thereby directing the airflow toward the surface of the one or more primary cover members. This air extracts the heat of the electric machine and is received via receiver openings of the one or more secondary covers. Thereafter the plurality of projections starts to direct the airflow toward the periphery of the cover assembly, while traveling from the receiver opening toward the periphery the surface of cover assembly dissipates the heat of the airflow into the atmosphere. By the time, the airflow reaches the periphery of the cover assembly, it loses all the heat it had extracted from the electric machine and is ready to be recirculated toward the electric machine to cool it. This cycle continues as long as the cover assembly is rotating. The one or more secondary cover members are configured to maintain a gap (G) between one or more primary cover members and the one or more secondary cover members. The gap (G) provide a pathway to the airflow to circulate inside the wheel assembly. A plurality of projections are disposed in the gap (G) between the one or more primary cover members and the one or more secondary cover members.
[0032] As per another embodiment of the present invention, the one or more secondary cover members comprise a left secondary cover member. The left secondary cover member comprises a plurality of connector openings and a left receiver opening. The left secondary cover member is configured to be mounted on a left primary cover member of the one or more primary cover members through the plurality of connecting members. A plurality of left mountings are disposed on a left primary cover member of the one or more primary cover member. The left secondary cover member is configured to receive an airflow, i.e. hot air from inside of the electric motor, via the left receiver opening.
[0033] As per another embodiment of the present invention, the one or more secondary cover members comprise a right secondary cover member. In an embodiment, the configuration of the right secondary cover member can be different for the left secondary cover member. Further, the right secondary cover member comprises a plurality of connector openings and a right receiver opening. In an embodiment the diameter of the right receiver opening can be greater than the diameter of left receiver opening, this configuration may be provided to accommodate a protrusion in the right receiver opening. In another embodiment, a gap may be maintained between the receiver opening and the protrusion. The right secondary cover member is configured to be mounted on a right primary cover member of the one or more primary cover members via the plurality of connecting members, where the right secondary cover member is configured to receive the airflow via the right receiver opening.
[0034] As per another embodiment of the present invention, the one or more primary cover members comprise a left primary cover member. Further, the left primary cover member comprises a left outer portion and a plurality of left mountings. The left outer portion is exposed to the atmosphere, thereby helping in the removal of heat from the cover assembly. The plurality of left mountings is disposed on an enclosed portion of the one or more primary cover members. The plurality of left mountings being configured to mount a left secondary cover member of the one or more secondary cover members.
[0035] As per another embodiment of the present invention, the one or more primary cover members comprises a right primary cover member. The right primary cover member comprises a right outer portion, which helps in dissipation of heat from the inside of the cover assembly and a protrusion. The right outer portion is exposed to the atmosphere and the right outer portion comprises a cavity. The cavity is configured to receive a brake unit of the wheel assembly. In an embodiment of the present invention the brake unit may include but is not limited to a drum brake, a disc brake, a hydraulic brake etc. The plurality of right mountings is configured to mount a right secondary cover member of the one or more secondary cover members. The protrusion comprises the opening, the opening is configured to receive the shaft member of the electric machine and the protrusion is disposed on an enclosed portion of the one or more primary cover members.
[0036] As per another embodiment of the present invention, the one or more primary cover members are configured to be mounted on a rotor ring of the motor through a plurality of connecting members received via a plurality of mount openings. Therefore, the one or more primary cover members will rotate whenever the rotor ring rotates. The plurality of mount openings is disposed on the periphery of the one or more primary cover members and the one or more primary cover members being configured to rotate integrally with the wheel rim.
[0037] As per another embodiment of the present invention, the plurality of projections is configured to direct airflow in a radially outward direction. The radially outward direction is a direction of the airflow from the left receiver openings and the right receiver toward a periphery of the one or more primary cover members. While entering the right and left receiver opening the airflow carries heat that it had extracted from the electric motor during operations. When the airflow travels toward the periphery, the plurality of projections helps it dissipate the heat via convection through the surface of the one or more primary cover members. In addition, the plurality of projections also increases the heat exchange/dissipation surface area of the cover assembly. By the time the airflow reaches the periphery it had cool down and circulated again toward the electric motor. When airflow reaches the inside of the periphery it is directed in an inward direction to cool the electric machine which in one embodiment is the electric motor, the inward direction is the direction of the airflow from the periphery toward the electric machine
[0038] As per another embodiment of the present invention, the plurality of projections is configured to be disposed on the one or more secondary cover members. In another embodiment, the plurality of projections may be disposed on the enclosed portion of the one or more primary cover members.
[0039] As per another embodiment of the present invention, an electric machine for a wheel assembly of a vehicle is provided. In an embodiment the electric machine may include but not limited to an electric motor. The electric machine comprises a rotating member, a shaft member and the cover assembly. In an embodiment of the present invention, the rotor member may be a rotor of a hub-mounted electric motor. The rotating member is configured to rotate a wheel rim a wheel assembly. The shaft member is configured to mount a cover assembly. A stator of the electric motor is mounted on the shaft. The cover assembly comprises one or more primary cover members and one or more secondary cover members. The one or more primary cover members are configured to enclose an electric machine and the one or more primary cover members are configured to receive a shaft member of the electric machine through an opening. The one or more primary cover members comprise an enclosed portion. The one or more primary cover members are configured to rotate freely on the shaft member. The one or more secondary cover members are configured to maintain a gap (G) between one or more primary cover members and the one or more secondary cover members. A plurality of projections are disposed in the gap (G) between the one or more primary cover members and the one or more secondary cover members.
[0040] As per another embodiment of the present invention, the electric machine receives electrical energy from an energy unit of a vehicle, as per an embodiment, the energy unit may include but not limited to a lithium-ion battery, a lead acid battery, a combination of both lithium ion and lead acid battery etc. and the cover assembly is configured to cool down the electric machine during operations.
[0041] As per another embodiment of the present invention, the wheel rim is configured with the wheel rim on which a tire is mounted. The one or more tyres are configured to rotate integrally with the wheel rim.
[0042] As per another embodiment of the present invention, the right primary cover member of one or more primary cover members comprising an outer portion, the outer portion being configured to receive the brake unit via a cavity.
[0043] In an embodiment of the present invention the brake unit may be disposed on the left primary cover member of the one or more primary cover member based on the configuration and characteristics of the vehicle.
[0044] The present subject matter is further described with reference to the accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter. Various configurations may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[0045] The foregoing disclosure is not intended to limit the present disclosure to the precise forms of particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure.
[0046] In the foregoing specification, the disclosure has been described with reference to specific embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosure. It is to be understood that the forms of the disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials processed or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “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.
[0047] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and would in no way be construed as limiting the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, etc.) are only used to aid the reader’s understanding of the present invention, and may not create limitations, particularly as to the position orientation, or use of the system and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.
[0048] Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken as identifiers, to assist the reader’s understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation, and/or modification relative to, or over, another element, embodiment, variation and/or modification.
[0049] It will also be appreciated that one or more of the elements depicted in the drawings/ figures can also be implemented in a more separated or integrated manner, or even removed, or rendered as inoperable in certain cases, as is useful in accordance with a particular application. The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. However, the disclosed invention is not limited to the present embodiments.
[0050] Figures 1 – 5 are taken together for discussion. A cover assembly (300, shown in Figures 15 and 16) for an electric machine is disclosed. In an embodiment of the present invention, the electric machine may be an electric motor. The cover assembly (300) comprises one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R). The one or more primary cover members (301L, 301R) are configured to enclose the electric machine, thereby providing a sealed enclosure to the cover assembly (300) and the one or more primary cover members (301L, 301R) are configured to receive a shaft member (201) of the electric machine through an opening (304). The one or more secondary cover members (303L, 303R) are configured to be mounted on the one or more primary cover members (301L, 301R). The one or more primary cover members (301L, 301R) comprise an enclosed portion (301E). The enclosed portion (301E) can include a plurality of projections (302). The plurality of projections (302) are configured to guide an airflow inside the cover assembly to cool the hot air inside motor and further the cooled air is recirculated to cool down the electric machine. The one or more primary cover members are configured to rotate freely on the shaft member (201). The one or more secondary cover members (303L, 303R) are configured to maintain a gap (G, shown in Figure – 14) between one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R). A plurality of projections (302) are disposed in the gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R).
[0051] As particularly shown in Figures 2 and 3, the one or more secondary cover members (303L, 303R) comprise a left secondary cover member (303L). The left secondary cover member (303L) comprises a plurality of connector openings (312) and a left receiver opening (313). The left secondary cover member (303L) is configured to be mounted on a left primary cover member (301L) of the one or more primary cover members (301L, 301R) through the plurality of connecting members (306). A plurality of left mountings (309L) are disposed on the left primary cover member (301L). The left secondary cover member (303L) is configured to receive an airflow via the left receiver opening (313) after which the airflow is further directed by the plurality of projections (302). Further, the left secondary cover member (303L) is configured to align the left receiver opening (313) with the opening (304) of the primary cover member (301L) upon being mounted to the primary cover member (301L).
[0052] As particularly shown in Figure 3 and 4, the one or more primary cover members (301L, 301R) comprise a left primary cover member (301L). Further, the left primary cover member (301L) comprises a left outer portion (308L) and a plurality of left mountings (309L). The left outer portion (308L) is exposed to the atmosphere. The plurality of left mountings (309L) is disposed on an enclosed portion (301E) of the one or more primary cover members (301L, 301R). The plurality of left mountings (309L) being configured to mount a left secondary cover member (303L) of the one or more secondary cover members (303L, 303R).
[0053] Figures 6- 10 are taken together for discussion. The one or more secondary cover members (303L, 303R) comprise a right secondary cover member (303R). Further, the right secondary cover member (303R) comprises a plurality of connector openings (312) and a right receiver opening (314). The right secondary cover member (303R) is configured to be mounted on a right primary cover member (301R) of the one or more primary cover members (301L, 301R) via the plurality of connecting members (306), where the right secondary cover member (303R) being configured to receive an airflow via the right receiver opening (314).
[0054] Further, the one or more primary cover members (301L, 301R) comprises a right primary cover member (301R). The right primary cover member (301R) comprises a right outer portion (308R) and a protrusion (311). The right outer portion (308R) is exposed to the atmosphere thereby dissipate the heat generated during the operation of the electric machine (not shown) and the right outer portion (308R) comprises a cavity (310). The cavity (310) is configured to receive a brake unit of the wheel assembly (400). In an embodiment of the present invention the brake unit may include but is not limited to a drum brake, a disc brake, a hydraulic brake etc. The plurality of right mountings (309R) is configured to mount a right secondary cover member (303R) of the one or more secondary cover members (303L, 303R). The protrusion (311) comprises the opening (304) and the protrusion (311) is disposed on the enclosed portion (310E).
[0055] Figures 11- 14 are taken together for discussion. The plurality of projections (302) are configured to be disposed between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R). In one embodiment, the plurality of protrusions (302) can be attached on the enclosed surface (301E) (shown in Figure 1 and 7) of the one or more primary cover members (301L, 301R). In the present embodiment, as shown in Figure 11 and 12, the plurality of protrusions (302) are configured to be attached to the one or more secondary cover members (303R, 303L). This configuration enables ease of access and servicing of the one or more primary cover members (301L, 301R). Thus, in this embodiment, the plurality of protrusions (302) are attached on the surface of the one or more secondary cover members (303R, 303L) that faces the enclosed portion (301E) of the one or more primary cover members (301R, 301L).
[0056] The plurality of projections (302) is configured to direct airflow in a radially outward direction. The radially outward direction is a direction of the airflow from the left receiver openings (313) and the right receiver (314) toward a periphery (307) of the one or more primary cover members (301L, 301R). While entering the right and left receiver opening (313, 314) the airflow carries heat that it had extracted from the electric machine during operations. When the airflow travels toward the periphery (307), the plurality of projections (302) helps it dissipate the heat via convection through the surface of the one or more primary cover members (301L, 301R). By the time the airflow reaches the periphery (307) it had cool down and ready to be circulated again toward the electric motor. When airflow reaches the inside of the periphery (307) it is directed in a radially inward direction to cool the electric machine which in one embodiment is the electric motor, the radially inward direction is the direction of the airflow from the periphery (307) toward the left and right receiver openings (313, 314).
[0057] Figures 15 – 17 are taken together for discussion. An electric machine (not shown) for a wheel assembly (400) of a vehicle (100) is provided. In an embodiment the electric machine may include but not limited to an electric motor. The electric machine comprises a rotating member, a shaft member (201) and the cover assembly (300). In an embodiment of the present invention, the rotor member may be a rotor of a hub-mounted electric motor. The rotating member is configured to rotate integrally with a wheel rim (401) of the wheel assembly (400). The shaft member (201) is configured to mount a cover assembly (300). The cover assembly (300) comprises one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R). The one or more primary cover members (301L, 301R) are configured to be mounted on the wheel rim (401) through a plurality of connecting members (306) received via a plurality of mount openings (305). Therefore, the cover assembly (300) will rotate whenever the rotor rotates. The plurality of mount openings (305) is disposed on a periphery (307) of the one or more primary cover members (301L, 301R) and the one or more primary cover members (301L, 301R) being configured to rotate integrally with the wheel rim (401). The one or more primary cover members (301L, 301R) are configured to enclose an electric machine and the one or more primary cover members (301L, 301R) are configured to receive a shaft member (201) of the electric machine through the opening (304). The one or more secondary cover members (303L, 303R) are configured to be mounted on the one or more primary cover members (301L, 301R). The one or more primary cover members (301L, 301R) comprise an enclosed portion (301E). The enclosed portion (301E) comprises a plurality of projections (302) the one or more primary cover members (301L, 301R) configured to rotate freely on the shaft member (201). The one or more secondary cover members (303L, 303R) are configured to maintain a gap (G) between one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R). The plurality of projections (302) are disposed in the gap (G) (Shown in Figure 14) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R).
[0058] The electric machine receives an electrical energy from an energy unit of a vehicle (100) and the cover assembly (300) is configured to cool down the electric machine during operations. In the present exemplary embodiment, the electric machine can be a wheel hub mounted motor. In a preferred embodiment, the electric machine can be an IP67-rated hub motor.
[0059] As particularly shown in Figures 15 – 17, a wheel assembly (400) of a vehicle (100) is provided. The wheel assembly (400) comprises a brake unit, the wheel rim and the cover assembly (300). The brake unit is configured to prevent a rotation of the wheel assembly (400). The wheel rim (401) is configured to receive an electric machine. The electric machine comprises a rotating member and a shaft member (201). The rotating member is configured to rotate integrally with the wheel rim (401). The shaft member (201) is configured to mount a cover assembly (300). The cover assembly (300) comprises one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R). The one or more primary cover members (301L, 301R) are configured to enclose the electric machine and the one or more primary cover members (301L, 301R) are configured to receive a shaft member (201) of the electric machine through an opening (304). The one or more secondary cover members (303L, 303R) are configured to be mounted on the one or more primary cover members (301L, 301R). The one or more primary cover members (301L, 301R) comprise an enclosed portion (301E). The enclosed portion (301E) comprises a plurality of projections (302) the one or more primary cover members (301L, 301R) configured to rotate freely on the shaft member (201). The one or more secondary cover members (303L, 303R) are configured to maintain a gap (G) between one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R). A plurality of projections (302) are disposed in the gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R).
[0060] The wheel rim (401) is configured to mount one or more tyres (102) on a periphery (403) of the wheel rim (401). The one or more tyres 102) are configured to rotate integrally with the wheel rim (401).
[0061] The right primary cover member (301R) of one or more primary cover members (301L, 301R) comprising an outer portion (308R), the outer portion (308R) being configured to receive the brake unit (402) via a cavity (310). In an embodiment of the present invention the brake unit may be disposed on the left primary cover member (301L) of the one or more primary cover member (301L, 301R) based on the configuration and characteristics of the vehicle (100).
[0062] According to the above disclosure, the present invention provides various advantages. In a preferred embodiment, the plurality of projections (302) disposed in the gap (G) between one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R) act as fins to increase the rate of convection and direct the airflow in a radial direction. This helps to cool the electric motor more effectively, especially in motors which may include IP67-rated motors which have no other means of cooling.
[0063] Further, the plurality of projections (302) are designed to minimize drag and noise. This is important for the vehicle (100) and other electric-powered devices, where efficiency and performance are key.
[0064] In an embodiment, the one or more primary cover members (301L, 301R) are made up of a lightweight and durable material, such as aluminium. This makes it ideal for use in electric vehicles as per an embodiment of the vehicle (100) and other electric-powered devices, where weight is a concern.
[0065] The one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R) with the plurality of projections (302) disposed between them can direct the hot air outwardly from the electric motor (as per an embodiment of the electric machine) more effectively for cooling of the hot air which is further recirculated for cooling the electric motor, this resolve the issue of overheating and thereby increase the range of electric vehicles. Overheating can also reduce the performance of electric motor. By cooling the motor more effectively, the one or more primary cover (301L, 301R) can help to improve the performance of electric vehicles and other electric-powered devices.
[0066] The one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R) with the plurality of projections (302) cool the electric motor more effectively, by creating an airflow circuit which improves the overall heat dissipation characteristics, in an embodiment the plurality of projections create a turbulence inside the cover assembly (300), this turbulent air soak the heat form the electric machine (which may be an electric motor in one embodiment) and dissipate it to the atmosphere through the surface area of the cover assembly (300), which dissipate the heat via conduction. This helps in extending the lifespan of electric vehicles and other electric-powered devices, which otherwise may be affected by the lifespan of the vehicle (100).
[0067] The one or more primary cover members (301L, 301R) and one or more secondary cover members (303L, 303R) with the help of the plurality of projections (302) cool the electric motor more can help reduce the noise level of electric vehicles and other electric-powered devices, which may be generated due to overheating.
[0068] Lastly the present disclosure, can help in cooling of electric machine which may be a motor as per an embodiment, reduction of noise, reduction in overheating, improving the performance, increasing the lifespan and range of the electric vehicle.
[0069] While the present invention has been shown and described with reference to the foregoing preferred embodiments, it will be apparent to those skilled in the art that changes in form, connection, and detail may be made therein without departing from the scope of the invention.
[0070] This written description uses examples to provide details on the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
[0071] It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in light of the above disclosure.

LIST OF REFERENCES

Reference Numeral Meaning
300 A cover assembly
301L A left primary cover member of one or more primary cover members
301R A right primary cover members of one or more primary cover members
302 A plurality of projections
303L A left secondary cover member of one or more secondary cover members
303R A right secondary cover member of one or more secondary cover members
304 An opening of a left primary cover member
305 A plurality of mount openings
306 A plurality of connecting members
307 A periphery of one or more primary cover members
308L A left outer portion of a left primary cover member
308R A right outer portion of a right primary cover member
309L A plurality of left mountings
309R A plurality of right mountings
310 A cavity
311 A protrusion of a right primary cover member
312 A plurality of connector openings
313 A left receiver opening of a left primary cover member
314 A right receiver opening of a right primary cover member
400 A wheel assembly
401 A wheel rim
403 A periphery of wheel rim
100 A vehicle
102 One or more tyres
G A gap between one or more primary cover members and one or more secondary cover members

, Claims:We claim:
1. A cover assembly (300) for an electric machine, the cover assembly (300) comprising:
one or more primary cover members (301L, 301R), the one or more primary cover members (301L, 301R) being configured to enclose the electric machine and
the one or more primary cover members (301L, 301R) being configured to receive a shaft member (201) of the electric machine through an opening (304), and the one or more primary cover members (301L, 301R) configured to rotate freely on the shaft member (201);
one or more secondary cover members (303L, 303R), the one or more secondary cover members (303L, 303R) being configured with the one or more primary cover members (301L, 301R),
wherein the one or more secondary cover members (303L, 303R) being configured to maintain a gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R); and
a plurality of projections (302) disposed in the gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R).
2. The cover assembly (300) as claimed in claim 1, wherein the one or more secondary cover members (303L, 303R) comprise a left secondary cover member (303L), the left secondary cover member (303L) comprising a plurality of connector openings (312) and a left receiver opening (313) and
the left secondary cover member (303L) being configured to be mounted on a left primary cover member (301L) of the one or more primary cover members (301L, 301R) through a plurality of connecting members (306) and a plurality of left mountings (309L) disposed on the left primary cover member (301L), and
the left secondary cover member (303L) being configured to receive an airflow via the left receiver opening (313).
3. The cover assembly (300) as claimed in claim 1, wherein the one or more secondary cover members (303L, 303R) comprise:
a right secondary cover member (303R), the right secondary cover member (303R) comprising a plurality of connector openings (312) and a right receiver opening (314),
the right secondary cover member (303R) being configured to be mounted on a right primary cover member (301R) of the one or more primary cover members (301L, 301R), via the plurality of connecting members (306) and
the right secondary cover member (303R) being configured to receive an airflow via the right receiver opening (314).
4. The cover assembly (300) as claimed in claim 1, wherein the one or more primary cover members (301L, 301R) comprising:
a right primary cover member (301R), the right primary cover member (301R) comprising:
a right outer portion (308R), the right outer portion (308R) being exposed to the atmosphere and the right outer portion (308R) comprising a cavity (310), the cavity (310) being configured to receive a brake unit of the wheel assembly (400);
a plurality of right mountings (309R), the plurality of right mountings being configured to mount a right secondary cover member (303R) of the one or more secondary cover members (303L, 303R); and
a protrusion (311), the protrusion (311) comprising the opening (304) and the protrusion (311) being disposed on an enclosed portion (310E) of the right primary cover member (301R).
5. The cover assembly (300) as claimed in claim 1, wherein the one or more primary cover members (301L, 301R) being configured to be mounted on corresponding wheel rim (401) of a wheel assembly (400) of a vehicle (100) through a plurality of connecting members (306) received via a plurality of mount openings (305),
the plurality of mount openings (305) being disposed on a periphery (307) of the one or more primary cover members (301L, 301R), and
the one or more primary cover members (301L, 301R) being configured to rotate integrally with the wheel rim (401).
6. The cover assembly (300) as claimed in claim 1, wherein the plurality of projections (302) being configured to direct an airflow in a radially outward direction, the radially outward direction being a direction of the airflow from left and right receiver openings (313, 314) of the one or more secondary cover members (303L, 303R) toward a periphery (307) of the one or more primary cover members (301L, 301R).
7. The cover assembly (300) as claimed in claim 1, wherein the plurality of projections (302) being configured to be disposed on the one or more secondary cover members (303L, 303R).
8. An electric machine for a wheel assembly (400) of a vehicle (100), the electric machine comprising:
a rotating member the rotating member being configured to rotate integrally with a rotor ring of the electric machine;
a shaft member (201), the shaft member (201) being configured to mount a cover assembly (300);
wherein the cover assembly (300) comprising:
one or more primary cover members (301L, 301R), the one or more primary cover members (301L, 301R) being configured to enclose the electric machine and
the one or more primary cover members (301L, 301R) being configured to receive a shaft member (201) of the electric machine, and the one or more primary cover members (301L, 301R) configured to rotate freely on the shaft member (201);

one or more secondary cover members (303L, 303R), the one or more secondary (303l, 303R) being configured to cover at least a portion of the electric machine;
wherein the one or more secondary cover members (303L, 303R) being configured to maintain a gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R); and
a plurality of projections (302) being disposed in the gap (G) between the one or more primary cover members (301L, 301R) and the one or more secondary cover members (303L, 303R).

Dated this 14th day of March 2024

[Digitally Signed]
Sudarshan Singh Shekhawat
IN/PA – 1611
Agent for the Applicant