Description:
FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

TITLE OF INVENTION
A SADDLE-TYPE VEHICLE

APPLICANT
TVS MOTOR COMPANY LIMITED, an Indian company, having its address at “Chaitanya”, No.12 Khader Nawaz Khan Road, Nungambakkam, Chennai 600 006, Tamil Nadu, India.

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

FIELD OF THE INVENTION
[001] The present invention relates to a saddle-type vehicle. More particularly, the present invention relates to the saddle-type vehicle having a power supply control device for controlling the electrical power while charging the vehicle.

BACKGROUND OF THE INVENTION
[002] Ensuring efficient, secure, and reliable charging operations for electric vehicles (EVs) requires effective control of electricity flow from the grid to the vehicle's battery system. This entails employing various technologies, protocols, and considerations to regulate electrical power and current throughout the charging procedure. In existing scenario, mainly two main methods of charging for vehicle batteries or energy storage units include a slow charging method and a fast charging method. When consumers have to consider buying electric vehicles, the charging time remains a crucial factor impacting/influencing their decisions. Currently, the quickest method to charge an EV is through high-power direct current (DC) fast charging. DC fast charging is distinct from alternating current (AC) charging and necessitates specific considerations for original equipment manufacturers (OEMs) while designing essential components of a vehicle's electrical system, such as charging inlets.
[003] Slower charging systems, such as AC Level 1 and AC Level 2, utilize alternating current (AC), which is the typical method of electricity delivery from the power grid and to homes. Charging rates for AC can vary from 12A to 80A in North America, following the SAE J1772 standard, while rates differ elsewhere based on regional standards like IEC 62196 or GB/T 20234. When EV owners are required to charge their vehicles at home, they connect an EV charger to the vehicle's charging inlet, with the EV's onboard charger converting AC power to DC to charge the battery.
[004] On the other hand, DC fast charging is predominantly used at commercial public charging stations, where AC power from the grid is converted to DC power. This allows DC current to flow directly to the EV's battery upon plugging in.
[005] As per the J1772 standard, DC fast charging has two levels: DC Level 1 for rates up to 80A, and DC Level 2, also known as Level 3 charging, for rates up to 500A.The difference in charging time between AC charging and DC fast charging is significant. For instance, AC Level 1 charging at 12A and 120VAC can deliver up to 1.4 kW, while AC Level 2 charging at 80A and 240V provides up to 19.2 kW. Even at the highest power level of AC charging (19.2 kW), it would take roughly five to six hours to fully charge a 100 kWh battery pack. In contrast, with DC fast charging at 500A and 400VDC, the same 100 kWh battery could reach full capacity in approximately 30 minutes. These charging times are expected to decrease further with advancements in battery technology, upgrades to 800V architecture, and improvements in charging infrastructure.
[006] Typically, electric vehicles are supplied with a cable featuring a standard domestic plug on one end or plug on the other end, facilitating the use of the onboard charger. Within this cable, there is a control box integrated for safety functionalities. In certain countries, cables lack a control box which are prohibited due to safety concerns, as there is no means to disconnect the vehicle from the socket in case of an onboard issue. However, traditional AC contactors are not suitable for use within the control boxes integrated into the charging cable, primarily due to their size and imposes the risk of damage or unintentional operation in case the cable is dropped.
[007] In existing vehicle’s charging configurations, the vehicle charging inlet cables are directly connected to battery terminals. Owing to such configuration, the vehicle charging inlet undergoes the current always whenever the battery is switched on. Since the vehicle charging inlet can be accessed by a user, it impedes potential risks of short circuits and other failure by external objects. Accordingly, it is implicit to cut off the connection from battery to vehicle charging inlet when it is not in use.
[008] It has also been observed that with slow charging operations, the potentiality of short circuit or malfunction while charging of the battery pack is limited. However, in fast charging operations such as when current rating is over 50 A, there is a strict need for control mechanisms for safe battery pack charging.
[009] It has been observed that owing to space constraints in a saddle-type vehicle, it remains a huge challenge in mounting of components of charging system of the vehicle including the cables/wiring harness. Also, routing the cable inside the vehicle for connecting the vehicle charging inlet and the battery packs with required length and terminals is cumbersome and enhances more complexity.
[010] Further, it has also been observed that there is a need of efficient and safe control mechanisms which may assist with fast charging of vehicle battery packs while ensuring that no short circuit occurs between the vehicle charging inlet and the battery pack and further improve the overall safety of the system.
[011] In view of the foregoing, there is a need to provide a saddle- type vehicle which overcomes at least the above-mentioned disadvantages and drawbacks.

SUMMARY OF THE INVENTION
[012] In one aspect of the invention, a saddle-type vehicle is disclosed. The saddle-type vehicle includes a head tube; a pair of main frame members; one or more battery packs and one or more power supply control devices. The pair of main frame members extends rearwardly from the head tube in a front-rear direction of the vehicle. The one or more power supply control devices are disposed in a space between the pair of main frame members. The one or more power supply control devices is electrically connected to the one or more battery packs and configured to control the electrical power being supplied to charge the one or more battery packs.
[013] In an embodiment, the one or more power supply control devices is operably connected to an output of a charging port of the vehicle and in communication with a control unit. The one or more power supply control devices is configured to control the flow of the electric power based on signals received from the control unit.
[014] In an embodiment, an output of the one or more power supply control device is connected to terminals of the one or more battery packs.
[015] In an embodiment, the one or more power supply control devices is a relay or an electromechanical switch.
[016] In an embodiment, the one or more power supply control devices is positioned in front of a vehicle seat in a rear-front direction of the vehicle.
[017] In an embodiment, the one or more power supply control devices is disposed above the one or more battery packs and oriented downwardly and towards the one or more battery packs when seen from a side view of the vehicle.
[018] In an embodiment, the saddle-type vehicle includes a fuse box disposed between the pair of main frame members and in proximity to the one or more power supply control devices. The fuse box is operably connected to the one or more power supply control devices.
[019] In an embodiment, the one or more power supply control devices is inclinedly towards a vehicle central axis when seen from a top of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[020] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 is a schematic cross sectional view of a front portion of an exemplary saddle type vehicle, in accordance with an embodiment of the present invention.
Figure 2a is an upper perspective view of a front portion of the vehicle illustrating disposition of the power supply control devices with respect to the main frame members, in accordance with an embodiment of the present invention.
Figure 2b is an exploded view of the components mounted on a front portion of the vehicle, in accordance with an embodiment of the present invention.
Figure 3 is a perspective view of the vehicle charging port illustrating electrical connections of the vehicle charging port and the power supply control devices, in accordance with an embodiment of the present invention.
Figures 4a-4c illustrate a top, perspective and side views of the power supply control device, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[021] The present invention relates to a saddle-type vehicle having power supply control devices disposed in a space between the pair of main frame members. The one or more power supply control devices are electrically connected to one or more battery packs and configured to control the electrical power being supplied to charge the one or more battery packs during charging of the battery packs. The power supply control devices control the charging of the vehicle’s battery packs. The electrical connections of components used for charging the battery packs of the vehicle are controlled and secured by the power supply control devices before supplying the power to battery such that the vehicle charging port, power supply control devices and battery packs are placed in vehicle closer to avoid power losses and excessive wire length. Disposing the power supply control devices and the battery packs in the space between the pair of main frame members, require a minimal length of wiring harness which is secured from damages and failures.
[022] Figure 1 is a schematic cross sectional view of a front portion of an exemplary saddle type vehicle.
[023] In the present invention, a longitudinal axis refers to a front to rear axis relative to a vehicle, defining a vehicle longitudinal direction while a lateral axis refers to a side to side, or left to right axis relative to the vehicle, defining a vehicle width direction. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Arrows provided in the top right corner of the figure 1 depicts direction with respect to the vehicle, wherein an arrow F denotes a front direction, an arrow R indicates a rearward direction, an arrow Up denotes an upward direction, an arrow Dw denotes a downward direction of the vehicle.
[024] The saddle-type vehicle 100 includes a frame assembly 101. The frame assembly 101 includes a head tube 102, a pair of main frame members 104a, 104b (shown in Figure 2a), a pair of down frame members 106, and a pair of seat rails 110 . The pair of main frame members 104a, 104b extends rearwardly from the head tube 102 in a front-rear direction of the vehicle 100. Each of the pair of main frame members 104a, 104b includes an outer surface 105a (shown in Figure 2a) and an inner surface 105b. Each of the pair of down frame members 106 extending downwardly from the headtube 102 and joined to rear ends of one of the main frame members 104a, 104b. The frame assembly 101 includes a deflector member 103 secured to portions of each of the pair down frame members 106 and the pair of the main frame members 104a, 104b. Each of the pair of down frame members 106 includes a portion extending parallely to the longitudinal axis of the vehicle 100. Said portions are interconnected through a support plate 108 attached to portions of each of the down frame members 106. The support plate 108 along with the downframe members 106 constitute a cradle structure for receiving a battery pack 120 of the vehicle 100. An upper side of the battery is supportably attached to the deflector member 130. In an embodiment, the frame assembly 101 includes a cross member 107 configured to be attached to portions of each of the pair of main frame members 104a, 104b. The cross member 107 is positioned adjacent to seat rail attachment portions of the pair of main frame members 104a, 104b.
[025] The battery pack 120 is provided for driving the vehicle 100. The battery pack 120 may be one or more depending on the requirements of the vehicle 100. The battery pack 120 includes battery connectors 125 being electrically connected to terminals of the battery pack 120.
[026] In an embodiment, one or more power supply control devices 150 disposed in a space between the pair of main frame members 104a, 104b i.e. inner surface side 105b of the each of the pair of main frame members 104a, 104b.
[027] In an embodiment, the one or more power supply control devices 150 being disposed above the one or more battery packs 120 and oriented downwardly and towards the one or more battery packs 120 when seen from a side view of the vehicle 100. The one or more power supply control devices 150 is electrically connected to the one or more battery packs 120 and configured to control the electrical power being supplied to charge the one or more battery packs 120. In a non-limiting example, the one or more power supply control devices 150 is a relay, an electromechanical switch or may be metal–oxide–semiconductor field-effect transistors (MOSFET).
[028] In an embodiment, an output of the one or more power supply control devices 150 is connected to terminals of the one or more battery packs 120. The one or more power supply control devices 150 is positioned in front of a vehicle seat (not shown) in a rear-front direction of the vehicle 100.
[029] In an embodiment, the one or more power supply control devices 150 being inclinedly towards a vehicle central axis when seen from a top of the vehicle 100.
[030] Referring to Figures 2a, 2b, a charging port 140 is disposed behind the head tube 102 and between the pair of main frame members 104a, 104b. The charging port 140 includes two inputs and two outputs. The inputs are configured to receive a charging plug (not shown) of a charger / charging station for charging the battery packs 120 of the vehicle.
[031] In a non-limiting example, the charging port 150 is a Low Extra Voltage Direct Current (LEVDC) type connector configured to supply DC power with 12V supply. The charging port 140 includes two power terminals 142, 144 i.e., one positive terminal 142 and one negative terminal 144 for receiving the current from a charging station. The charging port 140 includes five signal terminals 145 including two signal pins which are operably connect to the battery pack 120 of the vehicle. In a non-limiting example, the battery pack 120 is a 12V battery and transmits a transient current to the charging station to indicate that the output terminal is securely connected to the charging port 140. Another two signal pins are used for CAN communication for exchange of data related to parameters of the battery pack 120 and charging parameters between the charging station and the battery pack 120. Remaining one signal pin is used to establish a ground connection in avoidance of short circuit.
[032] In an embodiment, the charging port 140 is located in front of the vehicle seat, behind the head tube and in the centre of vehicle 100 and is oriented at an angle of 45° with respect to the longitudinal axis of the vehicle 100 when seen from a side of the vehicle 100. Such orientation provides ease of access to a user of the vehicle 100 in connecting the charging plug of the charging station. The charging port 140 is attached to inner surface 105b (shown in Figure 1) of each of the pair of main frame members 104a, 104b through a mounting bracket (M). The mounting bracket (M) is configured to receive a base portion (B) of the charging port 140.
[033] In an embodiment, two separate power supply control devices 150a, 150b i.e. two relays are provided. Both two separate relays 150a, 150b are connected with each of a positive and negative supply i.e., an output of the charging port 140. Both the relays 150a, 150b are positioned adjacent to the vehicle charging port 140 and separated away from each other by a distance along the lateral axis of the vehicle 100 to avoid short circuit connection. The outputs of each of the relays 150a, 150b are connected to battery cables which are connected to the terminals of the battery pack 120 through battery connectors 125. The relays 150a, 150b include coil connections being connected to a control unit (not shown) by which the relays are operated/controlled/actuated for charging the battery pack 120. The control unit obtains connection and power supply information from the charging station through signals and based on same, the power supply for charging the battery pack 120 is enabled by means of relay actuation by the control unit.
[034] In an embodiment, the vehicle 100 includes a fuse box 160 placed in proximity to the one or more power supply control devices 150. The fuse box 160 being operably connected to the one or more power supply control devices 150. As shown in Figure 2a, the fuse box 160 is disposed between the positive relay 150a and negative relay 150b to ensure operating currents of the relays 150a, 150b do not exceed a pre-set threshold current as required to safeguard the battery pack 120 or other electrical-electronic components of the vehicle 100.
[035] In an embodiment, the relays 150, 150b are configured to disconnect the charging or current flow from the charging station being supplied to the battery pack in the event any malfunction or fault communicated from the charging station to the control unit through a CAN communication. In a non-limiting system, the control unit is configured to identify and recognise a charger plug of a charging station being stored in a pre-stored database of the controller unit. If the charging station is not an authorized charging station, the relays 150a, 150b are configured to disconnect the electrical power being supplied to the battery pack 120 to ensure safety of the battery pack 120.
[036] In an embodiment, the relays 150a, 150 are disposed above the battery packs 120 or above air ducts (not shown) of the vehicle. The relays 150a, 150b are placed in front of the control unit in a rear-front direction of the vehicle 100. The relays 150a, 150b are placed between the vehicle charging port 140 and the battery pack 120 when seen from the side of the vehicle 100.
[037] Referring to Figure 3, the charging port 140 include the base portion (B) and a protruded portion 141 extending away from the base portion (B). The base portion (B) includes mounting recesses for mounting the charging port 140 on the mounting bracket (B) (shown in Figure 2b). The protruded portion 141a is configured to be engaged with a mating or engaging portion of the charging plug of the charging station. The terminals 142, 145 and the signal pins 145 of the charging port 140 are provided inside or within the protruded portion 141. The charging port 140 is connected to the power supply control devices 150 through a wiring harness (W). The output of the charging port 140 is connected to the inputs (P, N) of the wiring harness (W) connected to the power supply control devices 150. The signal pins 145 are connected to the ground and the control unit through cables (C1, C2).
[038] Figures 4a-4c illustrate a top, perspective and side views of the power supply control device 150, in accordance with an embodiment of the present invention. The power supply control device 150 includes a casing 151 having an attachment portion 155. The attachment portion 155 includes a recess 155a. The recess 155a is configured to receive fasteners, such as screw, nut and/or bolt for mounting the power supply control device 150 on the frame assembly of the vehicle 100. The power supply control device 150 includes input terminals 152 and output terminals 154.
[039] Referring back to Figure 2a, in an embodiment, the power supply control devices i.e., the relays 150a, 150b are disposed slightly inclined to ensure that the wiring harness (W) connecting the relays 150a, 150b to the battery pack 120 is further reduced. In a non-limiting example, the relays 150a, 150b are oriented towards the ground of the vehicle 100 or towards the battery pack 120 with an inclination angle of 30 degrees when seen from the side of the vehicle 100.
[040] In an embodiment, the relays 150a, 150b are disposed at a distance from each of the pair of main frame members 104a, 104b and are mounted on a portion of the vehicle charging port 140 to avoid any accidental contact with the pair of frame members 104a, 104b and prevent a short circuit. In a non-limiting example, each of the pair of main frame members 104a, 104b is typically the grounding member and hence earth currents are alleviated via the frame assembly 101. In another non-limiting example, a contact between the high voltage relays 150a, 150b and the wiring harness (W) (shown) in Figure 3 with the frame assembly is avoided by inclinedly providing the relays 150a, 150b towards the vehicle central axis i.e. away from each of the pair of main frame members 104a, 104b with an inclination of 10 degrees when seen from the top of the vehicle 100. Such inclination prevents risks of metal interference of the relays 150a, 150b with the pair of main frame members 104a, 104b.
[041] Advantageously, the present invention provides a saddle-type vehicle having one or more power supply control devices disposed in a space between the pair of main frame members and the one or more power supply control devices being electrically connected to the one or more battery packs and configured to control the electrical power being supplied to charge the one or more battery packs.
[042] The present invention provides enhanced performance facilitated by securing the length of wiring harness connecting the charging port and the battery pack using power supply control devices. This configuration not only improves the vehicle performance but also enhances the durability of the entire electrical system of the vehicle. Additionally, the present invention improves aesthetics of the vehicle. The serviceability of the components is notably improved by the present invention by providing an easy access to the power supply control devices from a top portion of the vehicle, enhancing maintenance efficiency. Moreover, manufacturability and ease of assembly are also improved, contributing to streamlined production processes. Further, ergonomic considerations of the vehicle ensure a comfortable and user-friendly experience for drivers and passengers alike.
[043] Furthermore, the present invention improves the safety of the battery packs by disconnecting the electrical power in cases of charging electrical current exceeding the safe threshold current value or detection of any malfunction or fault.
[044] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals
100 – Saddle-type Vehicle
101 – Frame Assembly
102 – Head tube
104a, 104b – Pair of main frame members
105a – Outer surface of the pair of main frame members
105b – Inner surface of the pai
106 – Pair of down frame members
107 – Cross member
108 – Support plate
110 – Pair of seat rails
120 – One or more battery packs
125 – Battery connectors
130 – Deflector member
140 – Charging port
141 – Protruded portion of the charging port
142, 144 – Power terminals of the charging port
145 – Signal pins of the charging port
150 – One or more power supply control devices
150a – Positive relay
150b – Negative relay
B – Base portion of the charging port
C1, C2 – Cables
M – Mounting bracket of the charging port
W – Wiring Harness
P, N – Inputs of the wiring harness
, Claims:WE CLAIM:
1. A saddle-type vehicle (100) comprising:
a head tube (102);
a pair of main frame members (104a, 104b) extending rearwardly from the head tube (102) in a front-rear direction of the vehicle (100);
one or more battery packs (120); and
one or more power supply control devices (150) disposed in a space between the pair of main frame members (104a, 104b), the one or more power supply control devices (150) being electrically connected to the one or more battery packs (120) and configured to control the electrical power being supplied to charge the one or more battery packs (120).

2. The saddle-type vehicle (100) as claimed in claim 1, wherein the one or more power supply control devices (150) being operably connected to an output of a charging port (140) of the vehicle (100) and in communication with a control unit, the one or more power supply control devices (140) being configured to control the flow of the electric power based on signals received from the control unit.

3. The saddle-type vehicle (100) as claimed in claim 1, wherein an output of the one or more power supply control device (150) being connected to terminals of the one or more battery packs (120).
4. The saddle-type vehicle (100) as claimed in claim 1, wherein the one or more power supply control devices (150) is a relay or an electromechanical switch.

5. The saddle-type vehicle (100) as claimed in claim 1, wherein the one or more power supply control devices (150) is positioned in front of a vehicle seat in a rear-front direction of the vehicle (100).

6. The saddle-type vehicle (100) as claimed in claim 1, wherein the one or more power supply control devices (150) being disposed above the one or more battery packs (120) and oriented downwardly and towards the one or more battery packs (120) when seen from a side view of the vehicle (100).

7. The saddle-type vehicle (100) as claimed in claim 1, comprises a fuse box (160) disposed between the pair of main frame members (104), and in proximity to the one or more power supply control devices (150), the fuse box (160) being operably connected to the one or more power supply control devices (150).

8. The saddle-type vehicle (100) as claimed in claim 1, wherein the one or more power supply control devices (150) being inclinedly towards a vehicle central axis when seen from a top of the vehicle (100).

Dated this 19th day of March 2024

TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471