Description:FIELD OF THE INVENTION

[0001] The present invention relates to supporting means. More specifically, the present invention relates to a support assembly for mounting of an electric drive unit while allowing easy access to each of the components for execution of maintenance activities.

BACKGROUND OF THE INVENTION

[0002] Electrically driven implements have been becoming increasingly commonplace with a rapid shift away from mechanisms powered by fossil fuels, prompted due to environmental concerns caused due to the burning of the fossil fuels. These electrically driven implements are provided with at least one electric drive unit, for imparting the actuation required for the realization of the desired end effect.

[0003] An electric drive unit fundamentally comprises an electric motor and a controller box for the management of the operation of the motor in accordance with the demands raised during the operation of the electrically driven implement.The electric motor may be one of AC (alternating current) motors including synchronous motors and induction motors, DC (direct current) motors including brushed motors and brushless motors, and universal motors, etc.

[0004] The controller box is associated with the electric motor designed for performing functions including power management, torque control, speed control, direction control, and communication and feedback, etc. The controller box is usually a combination of a plurality of parts including but not limited to an inverter in case of AC for converting DC power from a battery or other power source into AC power to drive the motor, a rectifier for DC (direct current) motors, a DC-DC converter, capacitors to store and smooth out electrical energy to ensure stable power delivery, various power transistors as switches to control the voltage and current supplied to the motor, busbars to conduct high current between components efficiently, microcontrollers or processors for processing inputs from sensors and executing control algorithms, DSP (digital signal processor) for data processing, control board to house the logic circuitry, fuses, circuit breakers, communication interfaces and control & sensor terminals. Thus, it becomes highly imperative to ensure the controller box is provided with a secure barrier protecting the parts from the external elements such as dust, moisture etc.

[0005] The numerous electronic parts of the controller introduce vulnerabilities to the electric drive unit which may include dust ingress
by infiltration of dust particles into the controller box through small gaps or unsealed areas. Accumulated dust interfere with the operation of sensitive components such as microcontrollers, capacitors, and power transistors, leading to overheating, short circuits, or degraded performance over time; penetration of moisture into the controller box, causing corrosion of metallic components like busbars, connectors, and circuit boards. Humidity may lead to condensation within the controller box, creating pathways for electrical arcing or short circuits; exposure to extreme temperatures, whether from external conditions or insufficient heat dissipation, causes heat-sensitive components such as DSPs, microcontrollers, and power transistors to malfunction or fail prematurely; environmental vibrations and mechanical shocks, especially in applications like vehicles or industrial machinery, can loosen connections, crack solder joints, or damage circuit boards; exposure to chemicals, such as oils, greases, or cleaning agents, degrade seals, corrode components, or compromise insulation, further increasing the risk of failure; the controller box, without proper shielding, is vulnerable to electromagnetic interference from nearby devices, which can disrupt the functionality of microcontrollers, processors, and communication interfaces.

[0006] The methodologies currently employed in the art for mounting electric drive units onto structures associated with the electrically driven implement powered by the electric drive unit, suffer from several significant drawbacks, which limit their performance, usability, and adoption in diverse applications.

[0007] One of the primary issues with existing mounting techniques is their lack of compactness. Many traditional mounting designs require substantial space to accommodate the electric motor and its controller box, thereby increasing the overall size of the arrangement. These mounting techniques involve separate, disjointed parts for the mounting of the motor and the controller box. This inefficiency in spatial utilization becomes a critical challenge in applications where compact designs are essential, such as in electric vehicles, portable industrial electrically driven implement, and other space-constrained environments. The inability to optimize space not only restricts the integration of electric drive units into such applications but also negatively impacts the aesthetic and ergonomic design of the electrically driven implement.

[0008] In addition to compactness, accessibility remains a major concern in the existing art. Many conventional mounting systems make it difficult to access the electric drive unit, components of the electric drive unit or parts of the electrically driven implement obscured by the electric drive unit, during installation or routine maintenance. This results in prolonged downtime, increased labor costs, and operational inefficiencies. In scenarios where frequent maintenance or part replacement is necessary, poor accessibility leading to substantial inconvenience for users and maintenance personnel alike.

[0009] Another critical drawback in existing mounting systems is their inability to adequately isolate vibrations generated by the electric motor. Vibration transmission from the motor to the electrically driven implement not only leads to increased wear and tear of the components but also compromises the overall performance of the implement. Vibrations cause noise, reduce user comfort, and, over time, lead to structural fatigue or failure. Current solutions often rely on makeshift or inadequately designed vibration isolation mechanisms that fail to address these issues effectively.

[0010] The present invention addresses these challenges by providing an improved mounting system specifically designed for electric drive units. This invention ensures that the electric drive unit is mounted in a compact and space-efficient manner, making it suitable for integration into space-limited applications. Additionally, it offers enhanced accessibility, simplifying the installation and maintenance processes and reducing downtime. The proposed system incorporates effective vibration isolation mechanisms to minimize wear, noise, and structural fatigue, thereby improving the reliability and operational lifespan of the electrically driven implement. Furthermore, the invention is designed to be versatile and adaptable, accommodating a wide range of electric motor and controller box configurations, thus reducing the need for customization and enabling seamless integration across diverse applications.

[0011] By addressing the limitations in compactness, accessibility, vibration and isolation, the present invention represents a significant advancement in the art, offering a robust and efficient solution for mounting electric drive units onto implement structures.

[0012] None of the mounting techniques of the prior art are provided with a user-friendly mechanism that allows the mounting of electric motor and the controller box within a shielded and compact volume while providing convenience for the accessing of the components of the electrical drive unit and the region in proximity of the electrical drive unit.

[0013] Therefore, there is a need in the art to overcome aforementioned shortcomings of the mounting structures. More specifically, there is a demand in the art for a manner of mounting of the electrical drive unit, which ensures a minimized footprint, safety against environmental elements while allowing convenience for execution of maintenance activities.

OBJECTS OF THE INVENTION

[0014] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0015] An object of the present invention is to develop a supporting assembly capable of supporting multiple components of an electric drive unit within a compact footprint.

[0016] Another object of the present invention is to support the various components of the electric drive unit while allowing convenient access to each of the components for performing maintenance activities.

[0017] Yet, another object of the proposed invention is to secure the electric drive in a manner that suppresses the vibrations induced during operation of the electric drive unit.

[0018] Another object of the present invention is to conceptualize a means of housing, resistant to corrosion, to prolong operational life of the electric drive unit.

[0019] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0020] This summary is provided to introduce concepts related to a support assembly designed to provide a turnkey solution for the mounting of an electric drive unit powering an equipment, in a secure manner to ensure minimal storage footprint and convenient access to the components the electric drive unit. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter.

[0021] The present invention relates to a support assembly for mounting of an electric drive unit onto a structure, the electric drive unit having an electric motor and a controller box connected with the motor, wherein the support assembly is provided with a frame adapted to be fastened with the structure in a rotatable manner, allowing a rotation of the frame with respect to the structure.

[0022] In an embodiment of the present invention, an enclosure is configured for housing the controller box within the enclosure, wherein the enclosure is developed with a means that enables the suspension of the enclosure within the frame.

[0023] In another embodiment of the instant invention, a cradle arm is incorporated underneath the frame, for mounting of the motor at end of the arm, beneath the enclosure, packing the entire electric drive unit within a minimised footprint, the cradle arm being mounted by means of a damping mount.

[0024] An embodiment of the support assembly is specifically configured within an electric vehicle for mounting of an electric drive unit powering the electric vehicle, onto a chassis of the electric vehicle, the support assembly having a frame adapted to be fastened with the chassis in a rotatable manner, by means of a plurality of hinges connected with a posterior edge of said frame, an enclosure configured for housing the controller box within the frame, a plurality of brackets attached with lateral surfaces of the enclosure, to enable suspending the enclosure within the frame, a cradle arm incorporated underneath the frame, for mounting of the motor on to a bespoke plate provided at end of the arm, wherein the arm is angled to position the motor beneath the enclosure, to maintain a compact footprint of the electric drive unit.

[0025] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 exemplarily illustrates a perspective view of a support assembly for mounting of an electric drive unit;
Figure 2 exemplarily illustrates an exploded view of the support assembly for mounting of an electric drive unit;
Figure 3 exemplarily illustrates a perspective view of the support assembly configured for mounting of the electric drive unit onto a chassis of an electric vehicle; and
Figure 4 exemplarily illustrates an enlarged view of the support assembly configured for mounting of the electric drive unit onto the chassis of said electric vehicle.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0028] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0029] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0030] The present invention relates to a support assembly for mounting of an electric drive unit onto a structure, wherein the electric drive unit primarily comprises an electric motor for providing actuation and a controller box associated with the electric motor for management of operations of said electric motor.

[0031] The instant support assembly is conceived to mount the electric drive assembly in a manner to allow for convenient access to the electric motor and the controller box for undertaking operations relating to inspection, repair, and replacement, etc., while ensuring a compact storage footprint of the electric drive unit.

[0032] The electric drive essentially comprises an electric motor for providing actuation to an equipment which is to be powered by the electric motor. The electric motor may be selected from AC (alternating current) motors including synchronous motors and induction motors, DC (direct current) motors including brushed motors and brushless motors, and universal motors, etc. The electric drive further comprises a controller box associated with electric motor, configured for performing functions including power management, speed control, torque control, speed control, direction control, and communication and feedback, etc.

[0033] The controller box typically is combination of parts including but not limited to an inverter in case of AC for converting DC power from a battery or other power source into AC power to drive the motor, a rectifier for DC motors, a DC-DC converter, capacitors to store and smooth out electrical energy to ensure stable power delivery, various power transistors as switches to control the voltage and current supplied to the motor, busbars to conduct high current between components efficiently, microcontrollers or processors for processing inputs from sensors and executing control algorithms, DSP (digital signal processor) for data processing, control board to house the logic circuitry, fuses, circuit breakers, communication interfaces and control & sensor terminals. Thus, it becomes highly imperative to ensure the controller box is provided with a secure barrier protecting the parts from the external elements such as dust, moisture etc.

[0034] Figure 1 exemplarily illustrates a perspective view of a support assembly 103 for mounting of an electric drive unit and the figure 2 exemplarily illustrates an exploded view of the support assembly 103 for mounting of an electric drive unit.

[0035] The support assembly 103 for mounting of an electric drive unit primarily comprises a frame 104 adapted to be fastened onto a structure 101 on which the electric drive is required to be supported, an enclosure 106 designed to be disposed within the frame 104, wherein the controller box 201 is situated in the enclosure 106, and a cradle arm 109 extending underneath the frame 104 for an attachment of the motor 102 at a bottom end of the cradle arm, thus enabling the mounting of the entire electric drive unit within a secure and compact storage footprint.

[0036] In a preferred embodiment of the instant invention, the frame 104 is a rectangular structure, the frame 104 includes a pair of rigid elongated members 104a, positioned parallel with one another, with an elongated bar 104b orthogonally connecting the ends of the members 104a directed away from the structure 101 to form a C-shaped frame 104, wherein the bar 104b is connected with the ends of the members 104a in a removable manner by means of fastening implements such as, screws, bolts, etc.

[0037] In an embodiment of the present invention, the frame 104 is a rectangular body composed of at least four rigid elongated members 104a attached with one another in an orthogonal manner to form a sturdy quadrilateral. In another embodiment of the present invention, the elongated members 104a are formed from rigid tubes having rectangular cross-section. In another embodiment of the instant invention, the elongated members 104a are formed from tubes having square cross-section. Members 104a having such polygonal cross-section are selected to impart a sturdy design to the frame 104 while ensuring the manufacturing process remains economical.

[0038] The frame 104 is designed to be attached with the structure 101 associated with the equipment which is being driven by the electric drive unit. Exemplarily, the structure 101 may refer to a chassis 302 of an electrically driven vehicle, a framework associated with a lifting mechanism, etc.

[0039] The posterior edge is provided with a plurality of hinges 105, which form the interface between the frame 104 and the structure 101 when the frame 104 is attached with the structure 101. This allows for the rotation of the frame 104 with respect to the structure 101. In the preferred embodiment of the instant invention, a pair of hinges 105 are configured to join the frame 104 with the structure 101. Other variations of the present invention may select the number of in accordance with the dimensions of the electric drive unit to be mounted.

[0040] The hinge 105 is a mechanical arrangement designed to facilitate rotational movement between the frame 104 and the structure 101, allowing the frame 104 to open or close relative to the structure 101. In an embodiment of the present invention, the basic structure 101 of the hinge 105 consists of two flat panes, referred to as leafs or hinge 105 plates, which are attached to the frame 104 and the structure 101. These panes are crafted with pre-drilled holes for screws or bolts to secure them in place. At the centre of the hinge 105 is a barrel, i.e., a cylindrical section formed by interlocking loops from each leaf, which serves as the pivot point. A pin, which is a cylindrical rod, is inserted through the knuckle, holding the panes together and acting as the axis of rotation. In some embodiments of the instant invention, the hinges 105 are provided with end caps to secure the pin and enhance aesthetics.

[0041] In another embodiment of the present invention, the frame 104 is designed to have a pair of parallel members 104a, with the hinges 105 provided at the posterior ends of the members. In yet another embodiment of the instant invention, the frame 104 is composed of three of said members 104a, arranged in a C-shape, with the hinges 105 provided at the posterior edge of the member 104a connecting the two parallel members.

[0042] Furthermore, the support assembly 103 for mounting of an electric drive unit onto the structure 101 is provided with an enclosure 106 within which the controller box 201 is stored, as illustrated in the exploded view of the support assembly presented in the Figure 2. In a referred embodiment of the present invention, the enclosure 106 is a hollow cuboidal housing, designed to be inserted into the frame 104 which is constructed to have a rectangular opening in order to suspend the controller box 201 within the frame 104. As the controller box 201 is housed within the enclosure 106 and the enclosure 106 being assembled with the frame 104, the rotation of the frame 104, allows easy access for maintenance of components installed beneath controller box 201 or the frame 104.

[0043] In the preferred embodiment of the present invention, the enclosure 106 is crafted from sheet metal to ensure the support assembly 103 remains economical, whereas in other embodiments of the present invention, the enclosure 106 may be manufactured by the process of casting, forging, stamping etc. The metallic construction of the enclosure 106 electromagnetically shields the controller box 201 thus preventing electromagnetic interference.

[0044] The lateral surfaces of the enclosure 106 are provided a plurality of brackets 107 to enable the suspension of the enclosure 106 in the opening of the frame 104. Each of the brackets 107 is an elongated flap bent to have an L-shaped cross-section, with the vertical portion of the flap attached with the lateral surface of the housing and the overhanging portion of the flap adapted to rest on the upper surface of the frame 104, thus stabilizing the position of the enclosure 106 in the frame 104.

[0045] In the preferred embodiment of the present support assembly 103, each of the two lateral surfaces of the enclosure 106 is provided with one elongated bracket 107 to ensure a stable placement of the enclosure 106. Other embodiments of the present invention employ a plurality of shorter brackets 107 arranged collinearly along the lateral surfaces.

[0046] A plurality of first fasteners 114 are constructed to pass through coincident openings crafted in the brackets 107 and the frame 104, in order to securely affix the enclosure 106 on the frame 104. Such an installation ensures the controller box 201 is not dislocated along any of the X, Y, or Z axes during an operation of the electric drive unit.

[0047] Each of the first fasteners 114 are configured with one or more grommet isolators 115, such that when the first fastener 114 is installed, the grommet isolators 115 are compressed between a head of the first fastener 114 and the upper surface of the frame 104.

[0048] The grommet isolator 115 is a type of vibration-dampening means implemented to minimize or eliminate the transmission of vibrations, shocks, and noise between the frame 104 and the enclosure 106 thus keeping the controller box 201 shielded from the vibration that may be generated from the operation of the equipment and travelling via the structure 101. The grommet isolator 115 combines the functionality of a typical grommet (used to protect holes or cables from abrasion) with vibration isolation properties.

[0049] The grommet isolator, in one embodiment of the present invention, is designed with several key components. The primary element is an elastomeric material, selected from rubber, silicone, or other flexible substances capable of absorbing and dissipating energy. This elasticity is essential for dampening vibrations and minimizing noise. At the core of the grommet isolator 115 is a central hole or sleeve, specifically designed to accommodate the first fastener 114 that passes through it. This feature prevents metal-to-metal contact, thereby reducing wear and the transfer of vibrations from the frame 104 to the enclosure 106. Additionally, the grommet isolator 115 is equipped with flanges or shoulders, which ensure the grommet remains securely seated within the mounting hole.

[0050] In order to further reduce the residual vibrations unabsorbed by the grommet isolators 115, a plurality of horn grommets 112 are disposed along vertical surfaces of the enclosure 106 to be compressed by the inner edges of the frame 104, further protecting the controller box 201 in the enclosure 106 from the vibrations travelling via the frame 104. Horn grommets 112 perform the same function as the grommet isolators 115, i.e., reduction of vibrations and noise and having a principally equivalent construction.

[0051] An upper opening of the enclosure 106 is provided with a rectangular cover 108 for sealing the interior of the enclosure 106 containing the controller box 201, from the external elements including dust, moisture etc. The upper edge of the enclosure 106 is provided with a continuous overhanging lip 113, wherein a plurality of apertures is crafted along the lip 113 and the cover 108 for allowing passage of a plurality of second fasteners 116 via said apertures to fasten the cover 108 with the enclosure 106.

[0052] Moreover, a cradle arm 109 is developed to hold the motor 102 in close proximity to the controller box 201. More specifically, the cradle arm 109 is an elongated and angled body attached underneath said frame 104, wherein the motor 102 is held at a bottom end of the cradle arm 109, to ensure the motor 102 and the controller box 201 are held within close proximity with one another and in a sturdy manner.

[0053] A plate 111 is provided at the bottom end of the cradle arm 109 which enables the attachment of the cradle arm 109 with a casing of the motor 102. A plurality of fixtures 117 are implemented to rigidly mount the motor 102 housed in the casing by affixing the casing with the cradle arm 109.

[0054] In an embodiment of the present invention, the cradle arm 109 is attached with the frame 104 in a removable manner by means of bolts and couplers, which allows the removal of the cradle arm 109, if demanded by a situation requiring disassembly of the support assembly 103 for maintenance purposes.

[0055] In a preferred embodiment of the instant invention, the cradle arm 109 is attached with the frame 104 by means of a damping mount 110 configured to support the motor 102 in a rigid manner while absorbing vibrations generated from the operation of the motor 102.

[0056] The damping mount 110 is composed of a connector 110a integrated with the frame 104, having a bushing 110b arranged within the connector 110a, with an opening formed within the connector 110a aligned with the bushing 110b. Such an arrangement specifically allows a passage of a stud 110c via said hollow region and said opening.

[0057] In a preferred embodiment of the present invention, the stud 110c is crafted to be threaded to allow for a coupling of the cradle arm 109 by a fastening of the stud 110c with an opening in an upper portion of the cradle arm 109.

[0058] The connector 110a is a U-shaped element with the open ends connected with a bottom portion of the frame 104 in a removable manner, enabling a complete disassembly of the present invention. The bottom part of the connector 110a is provided with the opening adapted to be aligned with the hollow region of the bushing 110b.

[0059] The bushing 110b is a resilient body designed to reduce friction and absorb vibrations generated from the operation of the motor 102, therefore reducing the vibrations radiating through the components of the present invention. In the preferred embodiment of the present invention the bushing 110b is a cylindrical body having a centrally-located hollow region, which is aligned with the opening of the connector 110a.

[0060] The stud 110c is an elongated component designed to pass through the hollow region of the bushing 110b and the opening of the connector 110a. In an embodiment of the present invention, the upper end of the stud 110c is affixed within the connector 110a by means of a nut fastened onto the stud 110c. In another embodiment of the present invention, a head integrated with the upper end of the stud 110c affixes the stud 110c within the connector 110a, while compressing the bushing 110b between the head and the bottom portion of the connector 110a.

[0061] In a preferred embodiment of the present disclosure, the plate 111 is constructed with a threaded hole facilitated engagement with a threaded lower end of the stud 110c, which enables the cradle arm 109 to remain rigidly attached with the frame 104 while providing structural support to the motor 102. The selected configuration of the damping mount 110 allows for the rotation of the cradle arm 109 as required for maintenance needs and for availing access to regions surrounding the electric drive unit.

[0062] In another embodiment of the present invention, the cradle arm 109 is welded with the frame 104 to provide a sturdy design of the support assembly 103. In yet another embodiment of the instant support assembly 103, the cradle arm 109 is attached underneath the frame 104 by means of a rotatable coupling, which allows for an outward rotation of the cradle arm 109 along with the motor 102 for creating an easy access to the motor 102.

[0063] The cradle arm 109 is preferably formed to be angled in order to support the motor 102 underneath the enclosure 106 while minimizing consumption of space under the enclosure 106. The angular design of the cradle arm 109 positions the motor 102 inwards with respect to the outer edges of the frame 104.

[0064] In the preferred embodiment of the present invention, the cradle arm 109 is made of an elongated and angled body having a circular cross-section. The cradle arm 109 is constructed with a hollow core to reduce the weight of the cradle and as well as the overall weight of the support assembly 103 and prevent twisting or torsional forces in longitudinal as well as latitudinal directions during equipment use.

[0065] In other embodiments of the present invention, pipes having rectangular or square cross-section are used to construct the cradle arm, or elongated curved solid bars are implemented as the cradle arm 109.

[0066] In yet another embodiment of the present invention, a plurality of cradle arms 109 is attached underneath the frame 104 to affix with the casing of the motor 102 at multiple points in order to provide enhanced sturdiness or to take into account an excessive mass of the motor 102.

[0067] The plate 111 provided at the bottom end of the cradle arm 109 is crafted in accordance with the design of the casing of the motor 102, to ensure compatibility. In an embodiment of the instant support assembly 103, the plate 111 is a rigid body having a plurality of holes enabling the installation of fixtures 117 such as bolts, screws etc. The specific shape of the plate 111 is selected to ensure compatibility with the casing of the motor 102. The fixtures 117 couple the motor 102 with the plate 111 without any intermediate components.

[0068] In a preferred embodiment of the present assembly, each of the side portions of the plate 111 are provided with a support panel 111a, specifically designed to be attached with the casing of the motor 102, thus facilitating the motor to be supported from a multiplicity of points on the casing providing enhanced rigidity. In an embodiment of the present invention, the fixtures 117 affix the panels 111a with the surfaces of the casing of the motor 102.

[0069] The frame 104, the enclosure 106 along with the cradle arm 109, in synergy, provide for a compact mounting solution for supporting the motor 102 along with the controller box 201 of the motor 102, which allows for an upward rotation of the entire arrangement by means of the hinges 105 to allow convenient access to the surfaces lying below the electric drive unit, which may be required for accessing parts of the equipment obscured by the electric drive unit or to enable storage of items within the unused irregularly-shaped residual space under the electric drive unit.

[0070] Since the frame 104 is the primary load bearing portion of the present support assembly 103, it is essential the operational life of the frame 104 is maximized. In the preferred embodiment of the present invention, the frame 104 is coated with at least one layer of a protective coating which safeguards the frame 104 against corrosive action of the ambient moisture and gases.

[0071] In the preferred embodiment of the instant support assembly 103, the protective coating is CED (cathodic electro deposition), also known as Electrophoretic Deposition (EPD) or E-coating, is a highly efficient coating process used for applying protective coating. CED method involves the electrochemical deposition of a coating material onto the frame 104, providing uniform coverage, corrosion resistance, and durability.

[0072] Applying protective coating by the CED process involves the frame 104 to be thoroughly cleaned to remove contaminants and ensure proper adhesion of the coating. Following the cleaning, the frame 104 is immersed in a water-based solution containing dispersed coating particles. The coating particles are selected from resins, pigments, etc. Further, an electrical supply is established, wherein the frame 104 acts as the cathode (negative electrode), while an anode (positive electrode) is also placed in the bath. When an electric current is applied, the coating particles are attracted to the surface of the frame 104 due to the electrostatic charge, causing the particles to form a uniform, even layer across the frame 104, even in hard-to-reach areas. Lastly, the excess coating is removed by rinsing the frame 104 and the coated frame 104 is then baked or cured to harden the coating and achieve the desired properties.

[0073] The implementation of CED imparts an array of benefits. An even coverage, including complex geometries and recessed areas of the frame 104 is ensured; protection against rust and environmental degradation is provided; enhanced adhesion for subsequent layers of paint or finish is imparted; and water-based solutions are utilised, thus less volatile organic compound (VOC) emissions are generated compared to other coating methods.

[0074] In an embodiment of the instant invention, the frame 104 is constructed by means of welling of the individual members 104a with one another by the process of MIG (metal inert gas) based fillet type welding, which provides the frame 104 with a high strength-to-weight ratio.

[0075] The support assembly 103 for mounting of an electric drive unit is capable of being implemented with any equipment where an electric motor 102 is utilised to generate power for actuation associated with the equipment. One of said instances is described herewith, wherein the support assembly 103 is installed with an electrically driven vehicle.

[0076] The figure 3 exemplarily illustrates a perspective view of the support assembly 103 configured for mounting of the electric drive unit onto a chassis 302 of an electric vehicle 301 and the Figure 4 exemplarily illustrates an enlarged view of the support assembly 103 configured for mounting of the electric drive unit onto the chassis 302 of said electric vehicle 301.

[0077] In an exemplary application of the present invention, the support assembly 103 is fastened onto a chassis 302 associated with the electric vehicle 301, wherein the electric vehicle 301 is driven by the electric drive unit comprising the motor 102 and the operations of the motor 102 are controlled by the controller box 201 associated with the motor 102. The support assembly 103 is specifically selected to be installed onto the chassis 302 of the electric vehicle 301 since the chassis 302 is the primary load bearing element of the vehicle, thus a rigid and sturdy surface is provided on which the support assembly 103 is mounted.

[0078] The frame 104 is joined with a rectilinear surface of the chassis 302 by means of the hinges 105, which enables the rotation of the frame 104 with respect to the chassis 302. The controller box 201 is positioned inside the enclosure 106 and the enclosure 106 is placed within the central opening, while keeping the brackets 107 attached with the enclosure 106 with the supper surface of the frame 104. The enclosure 106 is affixed with the frame 104 by fastening the first fasteners 114 through the brackets 107 and the frame 104, and then the lid is sealed by placing the cover 108 on top of the enclosure 106 and fastening the second fasteners 116 via the cover 108 and the lip 113 of the enclosure 106. Lastly, the motor 102 enclosing within the casing of the motor 102 is attached with cradle arm 109 below the frame 104, by passage of the fixtures 117 through the plate 111 and into the holes provided in the casing.

[0079] The described arrangement mounts the motor 102 along with the controller box 201 within a small storage footprint while allowing for the rotation of the frame 104 to enable access to the spaces underneath the frame 104 for storage purposes or for accessing other components of the vehicle.

[0080] The undertaking of the maintenance activities relating to the electric drive unit is further eased since the controller box 201 is accessible by a simple disassembly of the cover 108 by removal of the second fasteners 116 and motor 102 as well is accessed in a convenient manner by a lifting of the enclosure 106 after an unfastening of the first fasteners 114.

[0081] In an embodiment of the present invention, the first fasteners 114, the second fasteners 116 and the fixtures 117 are hexagonal flange bolts secured by nylon thick nuts. In another embodiment of the instant invention, button flange head screws are implemented as the first fasteners 114, the second fasteners 116 and the fixtures 117.

[0082] In a preferred embodiment of the instant invention, compatible bushings 110b are provided along with the first fasteners 114, the second fasteners 116 and the fixtures 117 to ensure a secure installation of the first fasteners 114, the second fasteners 116 and the fixtures 117.

[0083] In another preferred embodiment of the present invention, the first fasteners 114, the second fasteners 116 and the fixtures 117 are hardened by means of heat treatment, thus improving the longevity of the first fasteners 114, the second fasteners 116 and the fixtures 117 by enhancing resistance against stresses generated during the operation of the electric vehicle 301.

[0084] The method followed for a mounting of the electric drive unit powering the electric vehicle 301, onto the chassis 302 of the electric vehicle 301, includes firstly, fastening the frame 104 with the chassis 302 by means of the plurality of hinges 105, which is followed by positioning the enclosure within the frame 104 by aligning the brackets 107 with the members 104a in a secure manner by affixing the enclosure within the frame 104 by means of first fasteners 114. The controller box 201 is placed within the enclosure 106, wherein the enclosure is closed by the cover 108 in a rigid manner by means of the second fasteners 116. Further, the horn grommets 112 are inserted between the enclosure 106 and the frame 104. Next, the cradle arm 109 having the plate 111 is connected underneath the frame 104 by means of the damping mount 110, and the motor 102 is fastened with the plate 111 by means of the support panels 111a, wherein attachment of the motor 102 with the support panels 111a is established by means of the fixtures 117.

[0085] In an embodiment of the present invention, a means if provided for the routing of cables and wires associated with the motor 102 and the controller box 201. In one variation, a plurality of curved trays is disposed along the frame 104 for routing of the cables connecting the motor 102 with the controller box 201 in a secure manner, prevent the cable from being caught by foreign objects which may result in damage to the cables.

[0086] In another embodiment of the instant invention, a plurality of loops are disposed along the frame 104, via which the cables are passed to enable packing of the cable close to the electric drive unit this minimizing the footprint of the electric drive unit.

ADVANTAGES OF THE PRESENT INVENTION

[0087] One of the central advantages of the support assembly 103 for mounting of an electric drive unit is that an arrangement is designed which provided a singular turnkey solution for the mounting of the electric motor 102 along with the mounting of the controller box 201 operating the electric motor 102.

[0088] Yet another paramount benefit of the instant invention, is that the electric drive unit having the motor 102 and the controller box 201, is stored within a minimized footprint, which is especially advantageous in equipment such as electric vehicles 301, where the economical utilization of space is an utmost concern.

[0089] Often, where the electric drive unit is installed, the residual space remaining around he electric drive unit is wasted as the same is inaccessible and of irregular shape. The present invention provides for a solution wherein the electric drive unit is held against the structure 101, thus keeping the space below the electric drive unit vacant and unobstructed for storage purposes.

[0090] The space below the electric drive unit is enabled to be maximized temporarily, by the rotation of the upward rotation of the frame 104 with respect to the structure 101, causing the lifting of the entire electric drive unit, which may be demanded by situations where other components of the equipment are required to be accessed or objects are required to be traversed across the structure 101.

[0091] The present support system is designed in a manner to allow for convenient access to the controller box 201 and as well as the motor 102 for maintenance purposes. The controller box 201 is easily access by a mere removal of the cover 108 of the enclosure 106 and the motor 102 is conveniently reached by a removal of the enclosure 106 from the frame 104.

[0092] One more advantage of the present invention is that controller box 201 having the most crucial and fragile components of the electric drive unit are sealed from the harmful environmental elements such as moisture, dust gases, etc., therefore rendering the electric drive unit resistant to environmental elements.

[0093] The present support assembly 103 is further provided with means to absorb vibrations and noise generated by the equipment powered by the electric drive unit as well as the motor 102 itself to reduce generation of fatigue stressed and ensure an overall quiet operation of the equipment and the electric drive unit.

[0094] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention.

LIST OF REFERRAL NUMERALS WITH CORRESPONDING FEATURES:

• 101 – structure
• 102 – motor
• 103 – support assembly
• 104 – frame
• 104a - member
• 104b - bar
• 105 – hinge
• 106 – enclosure
• 107 – bracket
• 108 – cover
• 109 – cradle arm
• 110 - damping mount 110
• 110a - connector 110a
• 110b - bushing 110b
• 110c - stud
• 111 – plate
• 111a - panel
• 112 – horn grommet
• 113 – lip
• 114 – first fastener
• 115 – grommet isolator
• 116 – second fastener
• 117 – fixture
• 201 – controller box
• 301 – electric vehicle
• 302 – chassis , Claims:1) A support assembly 103 for mounting of an electric drive unit onto a structure 101, the electric drive unit having an electric motor 102 and a controller box 201 connected with the motor 102, the support assembly 103 comprising:

a) a frame 104 adapted to be fastened with the structure 101 in a rotatable manner, by means of one or more hinges 105 connected with a posterior edge of said frame 104;
b) an enclosure 106 configured for housing the controller box 201 within the frame 104;
c) one or more brackets 107 attached with lateral surfaces of the enclosure 106, to enable suspending the enclosure 106 within the frame 104; and
d) a cradle arm 109 attached underneath the frame 104, for securing of the motor 102 at end of the arm, beneath the enclosure 106.

2) The assembly as claimed in claim 1, wherein the frame 104 is crafted with a plurality of rigid elongated members 104a.

3) The assembly as claimed in claim 1, wherein a plurality of horn grommets 112 are arranged along lateral surface of the enclosure 106, aligned to interface with surfaces of the frame 104 to absorb vibrations.

4) The assembly as claimed in claim 1, wherein a cover 108 is provided over the enclosure 106 to shield an upper opening of the enclosure 106, mounted in a removable manner, to enable access to the controller box 201.

5) The assembly as claimed in claim 1, wherein a continuous overhanging lip 113 is disposed along an upper opening of the enclosure 106.

6) The assembly as claimed in claim 1, wherein a plurality of first fasteners 114 are arranged to affix the brackets 107 onto the frame 104, by passing through the cover 108 and the lip 113, to prevent a dislocation of the enclosure 106 with respect to the frame 104.

7) The assembly as claimed in claim 1, wherein the cradle arm 109 is crafted to be angled in order to position the motor 102 underneath the housing within a compact footprint.

8) The assembly as claimed in claim 1, wherein the cradle arm 109 is joined with the frame 104 by means of a damping mount 110.

9) The assembly as claimed in claim 8, wherein a bottom end of the cradle arm 109 is provided with a bespoke plate 111 for attachment of the motor 102 onto the plate 111 by means of fixtures 117.

10) The assembly as claimed in claim 9, wherein the each of the side portions of the plate 111 is provided with a support panel 111a to support the motor 102 at a multiplicity of points of the casing of the motor 102.

11) The assembly as claimed in claim 10, wherein the damping mount 110 comprises a connector 110a integrated with said frame 104, a bushing 110b disposed within said connector 110a, and a stud 110c inserted through the bushing 110b and an opening in the connector 110a, wherein a bottom end of said stud 110c is fastened with said plate 111.

12) The assembly as claimed in claim 1, wherein a plurality of grommet isolators 115 are configured along with the first fasteners 114 for dampening of vibrations and noise.

13) The assembly as claimed in claim 1, wherein a plurality of second fasteners 116 are provided to secured the cover 108 with the enclosure 106.

14) The assembly as claimed in claim 1, wherein a protective coating is applied on the frame 104 to enhance durability of the frame 104.

15) The assembly as claimed in claim 14, wherein the protective coating is applied by means of Cathodic Electro Deposition (CED) to safeguard the enclosure 106 against corrosion.

16) A support assembly 103 for mounting of an electric drive unit powering an electric vehicle 301, onto a chassis 302 of the electric vehicle 301, the electric drive unit having an electric motor 102 and a controller box 201 connected with the motor 102, the support assembly 103 comprising:

a) a frame 104 adapted to be fastened with the chassis 302 in a rotatable manner, by means of a plurality of hinges 105 connected with a posterior edge of said frame 104;
b) an enclosure 106 configured for housing the controller box 201 within the frame 104;
c) a plurality of brackets 107 attached with lateral surfaces of the enclosure 106, to enable suspending the enclosure 106 within the frame 104; and
d) a cradle arm 109 incorporated underneath the frame 104, for mounting of the motor 102 on to a bespoke plate 111 provided at end of the arm, wherein the arm is angled to position the motor 102 beneath the enclosure 106, to maintain a compact footprint of the electric drive unit, wherein the cradle arm 109 is attached with the frame 104 by means of a damping mount 110.

17) A method for mounting of the electric drive unit powering the electric vehicle 301, onto the chassis 302 of the electric vehicle 301, as claimed in claim 16, wherein the method comprises of steps:

a) fastening the frame 104 with the chassis 302 by means of the plurality of hinges 105;
b) positioning the enclosure within the frame 104 by aligning the brackets 107 with the members 104a;
c) affixing the enclosure within the frame 104 by means of first fasteners 114;
d) placing the controller box 201 within the enclosure 106;
e) closing the enclosure 106 by the cover 108;
f) securing the cover 108 with the enclosure 106 by means of the second fasteners 116;
g) inserting the horn grommets 112 between the enclosure 106 and the frame 104;
h) connecting the cradle arm 109 having the plate 111 underneath the frame 104 by means of the damping mount 110; and
i) fastening the motor 102 with the plate 111 by means of the support panels 111a, wherein attachment of the motor 102 with the support panels 111a is established by means of the fixtures 117.