DESC:Field of the invention
[0001] The present invention relates to two-wheelers. More specifically, the present invention relates to a conversion kit for modifying petrol-powered two-wheelers to electric-powered two-wheelers and a method for modifying so.

Background of the invention
[0002] Generally, Petrol-powered two-wheelers releases/emits carbon dioxide into the atmosphere. Therefore, presently electric-powered two-wheeler is used instead of the Petrol-powered two-wheeled vehicles, which has no emissions to the atmosphere. Additionally, due to rapid increase in the price of petroleum (petrol) and the importance of environmental protection, the electric-powered two-wheeler vehicle is an alternative option to the user.

[0003] Presently, the electric-powered two-wheelers are manufactured with a prime mover as a hub motor powered by a battery, usually fitted in a rear wheel of the two-wheeler. In the existing electric bikes, a hub motor is arranged on a rim portion or a side portion of the rear wheel of the two-wheeler. The hub motor consists of a permanent magnet, and the loss of magnetic property of the permanent magnet is directly proportional to heat & impact applied on the motor or due to exposure.

[0004] More specifically, when the electric two-wheelers are moving on rough roads, due to the rough road conditions, there will be mechanical jerks or sudden impacts on the hub motor as the hub motor is located on the rear wheel. As a result, more wear & tear occurs in the hub motor, and the permanent magnet may lose or reduce its magnetism.

[0005] Generally (in the present existing technologies), to convert the fuel-driven bike to the electric bike, an electric bike kit arrangement is used and installed in the bike accordingly. The electric bike kit arrangement includes a hub motor, one or more batteries and an electronic control unit (processor or related circuitry). An engine of the fuel-driven bike is replaced with a hub motor powered by a battery. The Hub motor is permanently arranged on the rear wheel of the electric bike. When the electric bikes travel on rough roads, the rough road conditions create jerks on the hub motor as the hub motor is located on the rear wheel. As a result, more wear & tear take place in the hub motor.

[0006] Therefore, there is a need for a conversion kit for modifying Petrol-powered two-wheelers to electrically powered two-wheelers, which overcomes the problems of the prior art.

Objects of the invention
[0007] An object of the present invention is to provide a conversion kit for modifying Petrol-powered two-wheelers to electrically powered two-wheelers.

[0008] Another object of the present invention is to provide a conversion kit for extending the life/reliability of a prime mover of a modified electrical two-wheeler compared to existing practices in electrical two-wheelers.

[0009] Another object of the present invention is to provide the conversion kit for ease of repair cum maintenance activity of a modified electrical two-wheeler compared to current practices (use of a hub motor fitted in a rear-wheel of electrical two-wheelers).

[0010] Another object of the present invention is to provide an arrangement for easy removal/fitment of an energy storage unit (power source) in an electric two-wheeler.

Summary of the invention

[0011] According to the present invention, a conversion kit for modifying a petrol-powered two-wheeler to an electric two-wheeler is provided. The conversion kit includes a prime mover, a power transmission mechanism, an electronic control unit and one or more energy storage unit.
[0012] In an embodiment, the prime mover of the kit is mounted on a chassis of the two-wheeler. The prime mover may be arranged inside a casing. A shaft of the prime mover is positioned coaxially with respect to the rear wheel of the two wheeler. The prime mover can be a motor. In the kit provided by the present invention, the Motor is a brushless direct current (BLDC) motor.

[0013] In one more embodiment, the power transmission mechanism is connected to the prime mover, and a rear-wheel. The power transmission mechanism can be a belt & pulleys mechanism, a rope & pulleys mechanism, a Chains & sprockets mechanism, Gears & Gear trains mechanism or a shaft & coupling mechanism.

[0014] In one more embodiment, the energy storage unit is mounted on the chassis. The energy storage unit can be a battery unit. The energy storage unit provides power to the prime mover. The energy storage unit may be connected to other accessories of the two-wheeler like headlight, indicators, speedometer, horn, taillight and electronic control unit etc., to provide power thereto. In the kit arrangement provided by the present invention, the energy storage unit is removable.

[0015] In one more embodiment, the electronic control unit is connected to the energy storage unit and the prime mover. The electronic control unit is for controlling the performance and operation characteristics of the prime mover and the energy storage unit.
[0016] In an alternative embodiment, the kit includes a communication module. The communication module is connected to the electronic control unit. The communication module enables the consumer to know the current status of the energy storage unit.
[0017] In a preferred embodiment, the kit arrangement includes a speed sensor, a temperature sensor, a processor and a display. The speed sensor, the temperature sensor and the display are connected to the processor. The speed sensor is arranged on a frame near a front wheel and adapted to sense the speed of the two-wheeler and sends the signals to the processor.

Brief description of drawings
[0018] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:

[0019] Figure 1 shows schematic view of conversion kit installed on modified two-wheeler (motorcycle); and

[0020] Figure 2 shows schematic view conversion kit installed on the modified two-wheelers (moped).

[0021] Figure 3 shows a schematic block diagram of the internal control circuit of the conversion kit.

[0022] Figure 4 shows a flow chart for a method for modifying a petrol-powered two-wheeler to an electrically powered two-wheeler in accordance with the present invention;

Detailed description of the invention
[0023] An embodiment of this invention, illustrating its features, will now be described in detail. The words "comprising," "having," "containing," and "including," and other forms thereof are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

[0024] The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0025] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.
[0026] The present invention provides a conversion kit for modifying a petrol-powered two-wheeler to an electrically powered two-wheeler. The conversion kit is easy to install on an existing petrol-powered two wheeler. Further, the repair and maintenance activity of the conversion kit is easy with respect to existing electric two wheeler. Furthermore, the conversion kit is arranged in such a way that the standard components of the two wheeler need not to be removed in order to maintain the strength of the two wheeler.

[0027] Referring now to Figure 1, a conversion kit (100), herein after referred to as a kit (100) for modifying a petrol-powered two-wheeler (100a) to an electrically powered two-wheeler in accordance with the present invention is illustrated. The kit (100) includes a prime mover (110a), a power transmission mechanism (160a), an electronic control unit (ECU) (140) and one or more energy storage unit (120a).

[0028] In a first embodiment, the conversion kit (100) is installed on the petrol-powered two wheeler (100a) as shown in figure 1. In the shown embodiment, the petrol-powered two-wheeler is a motorcycle (100a). The motorcycle (100a) used here inlcudes standard components such as an Internal combustion engine, an exhaust silenser, chassis, a front and a rear wheel, fuel tank and other accessories such as a headlamp, a tail light, turn indicators, and a display. The IC- engine (internal combustion engine) and a silencer of the motorcycle (100a) are removed from the motorcycle (100a). Alternatively, a fuel tank or any such accessories of the motorcycle (100a), which are essential for fuel-driven operations of the motorcycle (100a), are removed to reduce the weight of the motorcycle (100a).
[0029] In the embodiment, the prime mover (110a) of the kit (100) is mounted on a chassis (160a) of the motorcycle (100a) as shown in figure 1. A separate casing may be arranged around the prime mover (110a) for protecting the prime mover from vehicle vibrations. Further, a shaft of the prime mover (110a) is positioned coaxially with respect to the rear wheel of the motorcycle (130a)as shown in figure 1. As the prime mover is mounted on the chassis (160a), the construction does not affect any of the standard vehicle components. The prime mover (110a) can be a motor (112a). In the kit (100) provided by the present invention, the motor (112a) is a brushless direct current (BLDC) motor. The BLDC motor (112a) with an electronic commutator is small in dimensions and having less weight which makes the motor assembly easy to install on the chassis (160a) of the two wheeler (100a) as it occupies less space on the chassis (160a). In the present embodiment, the BLDC Motor is used in a Mid-Mounted configuration on the motorcycle (100a).
[0030] In an alternative embodiment, the motor can be an DC motor or dual motors or any such motors cable to drive the wheel using the power from the energy storage unit (120a) with respective accessories (DC-DC convertors) connected there-between accordingly. The kit (10) includes the voltage or electrical converters according to the various types of batteries and the related prime movers (110a).

[0031] An accelerator mechanism (300) is operably connected to the energy storage unit (120a) and the prime mover (110a). The accelerator mechanism (300) is manually manipulated to increase and decrease the revolutions of the rear wheel (130a) when power is provided by the energy storage unit to the prime mover (110a).

[0032] In the embodiment as shown in figure 1, the power transmission mechanism (160a) is adapted to connect to the shaft of the prime mover (110a), and a rear-wheel (130a) of the motorcycle (100a). The power transmission mechanism (160a) is for transmitting power from the prime mover (110a) to the rear wheel (130a) of motorcycle. The power transmission mechanism (160a) can be a belt & pulleys mechanism, a rope & pulleys mechanism, a Chains & sprockets mechanism, Gears & Gear trains mechanism or a shaft & coupling mechanism. In the present embodiment, a chain and sprocket mechanism is used to connect the shaft of the prime mover (110a) and the rear wheel (130a) of the motorcycle (100a).
[0033] Further referring to figure 1, in the embodiment, the energy storage unit (120a) is mounted on the chassis (180a). The energy storage unit (120a) can be a battery. The energy storage unit (120a) provides power to the prime mover (110a). It is obvious to the person skilled in the art to use a lithium ion polymer, nickel-chromium, lead acid or other suitable type of batteries. The energy storage unit (120a) may be connected to other accessories of the two-wheeler (100a) like headlight, indicators, speedometer, horn, taillight and electronic control unit etc., to provide power thereto. The energy storage unit (120a) is removably configured on the chassis (180a). The weight of the energy storage unit (120a) may be around 15 to 20kgs. When the battery is discharged the user can easily remove and replace the charged energy storage unit (120a).

[0034] Similarly, in a second embodiment, as shown in figure 2 the conversion kit (100) is installed on the petrol powered moped (100b). The moped (100b) includes standerd components such as an Internal combustion engine, an exhaust silenser, chassis, a front and a rear wheel, a storage box, a fuel tank and other accessories such as a headlamp, a tail light, turn indicators, and a display. The IC- engine (internal combustion engine) and a silencer of the moped (100b) are removed from the moped (100b). Alternatively, a fuel tank or any such accessories of the moped (100b), which are essential for fuel-driven operations of the moped (100b), are removed to reduce the weight of the moped (100b).

[0035] In the embodiment, the prime mover (110b) of the kit (100) is mounted on a chassis (180b) of the moped (100b) as shown in figure 2. More specifically, the shaft of the prime mover (110b) is positioned coaxially with respect to the rear wheel of the moped (100b) as shown in the figure 2. The prime mover (100b) can be a motor (112b). In the kit (100) provided by the present invention, the motor (112b) is a brushless direct current (BLDC) motor. In the present embodiment, the BLDC Motor is used in a Mid-Mounted configuration on the moped (100b).

[0036] An accelerator mechanism (300) is operably connected to the energy storage unit (120b) and the prime mover (110b). the accelerator mechanism (300) is manually manipulated to increase and decrease the revolutions of the rear wheel (130b) when power is provided by the energy storage unit to the prime mover (110b).

[0037] In the embodiment, the power transmission mechanism (160b) is adapted to connect to a shaft of the prime mover (110b), and a rear-wheel (130b) of the moped (100b) as shown in figure 2.

[0038] According to figure 2 in the embodiment, the energy storage unit (120b) is mounted under the storage box of the moped (100b). The energy storage unit (120b) can be a battery. In the kit arrangement (100) provided by the present invention, the energy storage unit (120b) is removable.
[0039] Now according to one or more embodiments disclosed above, the electronic control unit (140) is connected to the energy storage unit (120a/120b) and the prime mover (110a/110b).

[0040] The electronic control unit (140) controls one or more of the electrical systems or subsystems in the vehicle. The electronic control unit (140) depending on the detected operating variables of the motor vehicle, generates various motor vehicle functions, for example, by generating control signals for accelerator mechanism (300) or to carry out a self-diagnosis or error checking of the control device.

[0041] The electronic control unit (140) is the brain of the proposed conversion kit (100). The electronic control unit (140) converts user's signals for requirements of speed, to output and controlling all aspects of the kit (100). The electronic control unit (140) is for controlling the performance and operation characteristics of the prime mover (110a/110b) and the energy storage unit (120a/120b). The electronic control unit (140) is used to regulate the motor operations such as speed and torque. The electronic control unit (140) includes a microcontroller, a power mosfet, a transistor and other active and passive components. The BLDC motor (112a/112b) do not need brushes or slip rings for commutation. As a result, the electronic control unit (140) provides the commutation. The electronic control unit (140) is configured with hardware and software elements to operate accordingly.
[0042] In an alternative embodiment, the kit (100) includes a communication module (142). The communication module (142) is connected to the electronic control unit (140). The communication module (142) enables the consumer to know the current status of the energy storage unit (120a/120b).
[0043] In the preferred embodiment, the kit (100) includes a speed sensor (144), a temperature sensor (146) and a processor (not shown) and a display (148). The speed sensor (144), the temperature sensor (146) and the display (148) are connected to the processor (not shown). The speed sensor (144) is arranged on a frame (not numbered) near a front wheel and adapted to sense the speed of the two-wheeler (100a/100b) and sends the signals to the processor.
[0044] Similarly, the temperature sensor (146) is arranged near the prime mover (110a/110b) to measure the temperature of the prime mover (110a/110b). The sensed signals are sent to the processor. The processor provided the details of the sensed speed of the two-wheeler (100a/100b) and sensed the temperature of the prime mover (110a/110b) to the display (148). The display (148) displays the speed of the two-wheeler (100a/100b) and the temperature of the prime mover (110a/110b) thereon.
[0045] Now referring to figure 3, the internal circuit of the conversion kit is described. The circuit shows the energy storage unit connectivity to the communication module. The communication module may include a voltage sensor, a current sensor, and a memory unit for supplying power. Further a 4G lte module is connected to the communication module for transfering data to the display (148). The energy storage unit (120a/120b)is connected to the DC-DC converter. The DC-DC converter suplies power to a handlebar switch group. The handlebar switch group includes a headlamp switch, turn indicator, fog lamp switch and horn switch. The energy storage unit (120a/120b) is further connected to the motor controller. The motor controller is connected to the BLDC motor and throttle.
[0046] Further, according to an embodiment, a method (200) of installing a conversion kit (100) for modifying the petrol powered two wheeler to the electrically powered two wheeler is described. For the sake of brevity, the method (200) is described in conjunction with the conversion kit (100) described above.
[0047] The method starts at step 210.
[0048] At step 220 the vehicle components, such as IC-Engine, the silenser, the fuel tank or any such accessories essential for fuel driven operations of the petrol-powered two wheeler (the moped and the motorcycle), are removed to reduce the weight.
[0049] At step 230 the prime mover (110a, 110b) is mounted on a chassis (180a,180b) of the petrol powered two wheeler (100a/100b).
[0050] At step 240 the power transmission mechanism (160a/160b) is connected to the prime mover (110a/110b) and a rear wheel (130a/130b) of the petrol powered two wheeler (100a/100b).
[0051] At step 250 the energy storage unit (120a) is mounted on the chassis (180a) of the petrol powered motorcycle (100a). In the alternative example, the energy storage unit (120b) is mounted under the storage box of the moped (100b).
[0052] At step 260 the electronic control unit (140) is connected to the energy storage unit (120a/120b) and the prime mover (110a/110b) for controlling the performance and operation characteristics of the prime mover (110a/110b) and the energy storage unit (120a/120b). The electronic control unit (140) is used to regulate the motor operations such as speed and torque. Thereby converting the petrol powered two-wheeler to an electric powered two-wheeler.
[0053] The method ends at step 270
[0054] By following the steps (210- 270) of the method (100), the petrol-powered two-wheeler (150) can be modified to an electrically powered two-wheeler (170) (refer to figure 3a and 3b).
[0055] The present invention has the advantage of providing the conversion kit (100) for modifying petrol-powered two-wheeler to the electric two-wheeler (100a/100b). As the BLDC Motor (112a/112b) is located on the chassis (180a/180b), the chassis (180a/180b) and shock absorbers of the two-wheeler (100a/100b) will take most of the impact that arises due to jerks or sudden impacts while driving on rough roads, thereby reducing the impact on the prime mover (110a/110b). The location of the motor (112a/112b) also protects a permanent magnet of the motor (112a/112b) from typical road heat by placing it further away from the road (where the bike is travelling on). Hence, the life of a prime mover (110a/110b) of the modified electrical two-wheeler is more compared to existing electrical two-wheelers.
[0056] Furthermore, by using modified existing power transmission systems (160a/160b), the wheels of the two-wheeler (100a/100b) are not removed from the two-wheeler (100a/100b) for modifying the petrol-powered two-wheeler to the electrically powered two-wheeler (100a/100b). Due to this, a mechanic with less technical efficacy / a tyre repairman can easily fix nominal issues with the two-wheeler (100a/100b). Hence, the repair or maintenance activity of the modified electrical two-wheeler (100a/100b) is easier compared to existing electrical two-wheelers.
[0057] As the energy storage unit (120a/120b) of the electrically powered vehicle (100a/100b) is removable, a user (rider) of the two-wheeler (100a/100b) can remove and replace the energy storage unit (120a/120b) easily without any hurdles.
[0058] Further, all versions (the proposed kit for motorcycle or mopeds) will have to meet current standards, rules, regulations and codes as a necessary part of Automotive Industry Standards (AIS) and to be in compliance with the nature and scope of invention as detailed in related filings. The AIS compliance of the original 2-wheeler remains in place, and additional AIS complied kit (for the proposed conversion Kit) ensures that the 2-wheelers are roadworthy.
[0059] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or limit the present invention to the precise forms disclosed, and obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present invention and its practical application and thereby enable others skilled in the art to best utilise the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.
,CLAIMS:We Claim
1. A conversion kit (100) for modifying a petrol-powered two-wheeler to an electric two-wheeler, the kit comprising:
a prime mover (110a/110b) mountable on a chassis (180a/180b) of the petrol powered two wheeler (100a/100b);
a transmission mechanism (160a/160b) adapted to connect to a shaft of the prime mover (110a/110b) for engaging with a rear wheel (130a/130b) of the vehicle (100a/100b);
an energy storage unit (120a/120b) removably mounted on the chassis (180a/180b) of the vehicle (100a/100b), the energy storage unit (120a/120b) is connected to the prime mover (110a/110b) for supplying power to the prime mover (110a/110b); and
an electronic control unit (140) connected to the energy storage unit (120a/120b) and the prime mover (110a/110b) for controlling the performance and operation of the prime mover (110a/110b) and the energy storage unit (120a/120b); and
an accelerator mechanism (300) operably connected to the energy storage unit (120a/120b) and the prime mover (110a/110b), the accelerator mechanism (300) is manually manipulated to increase and decrease the revolutions of the rear wheel (130a/130b) when power is provided by the energy storage unit to the prime mover (110a/110b).

2. The conversion kit (100) as claimed in claim 1, wherein a shaft of the prime mover (110a/110b) is positioned coaxially with respect to the rear wheel (130a/130b).

3. The conversion kit (100) as claimed in claim 1, wherein a display (148) is connected to the electronic control unit (140) for providing details regarding the available energy status.

4. The conversion kit (100) as claimed in claim 1, wherein the electronic control unit (140) includes a communication module (142) for transferring data regarding available energy status to the display (148).