DESC:TECHNICAL FIELD
[0001] The present subject matter relates generally to a vehicle, and more particularly but not exclusively relates to a controller of the vehicle.
BACKGROUND 5
[0002] Generally, the major components of an electric vehicle or hybrid vehicle system include a motor, a controller, a power source, a charger, and a drive train. The controller is the brain of the electric vehicle. The controller is employed to regulate the torque generated by the motor of the electric vehicle by controlling the flow of energy from the power source to the motor. The controller calculates the 10 amount of energy needed by the vehicle to go smoothly on the road, based on the inputs received from the rider of the vehicle. The controller is connected to the power source and the motor through a wiring harness required for transmitting the power from the power source to the motor. With an increasing demand of the compact vehicles with high functionality, particularly for compact electric and 15 hybrid vehicle, the packaging layout of the vehicles is extensively explored and been worked upon to provide maximum vehicle performance and also to safeguard from any type of accidents.
BRIEF DESCRIPTION OF THE DRAWINGS 20
[0003] The details are described with reference to an embodiment of a two-wheeled electric vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components.
[0004] Figure 1(a) exemplarily illustrates a perspective right side view of a two-wheeled electric vehicle. 25
[0005] Figure 1(b) exemplarily illustrates a perspective left side view of a two-wheeled electric vehicle.
[0006] Figure 2 (a) exemplarily illustrates a perspective front view of the mounting means of the controller on the frame assembly of the vehicle.
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[0007] Figure 2(b) exemplarily illustrates a perspective rear view of the mounting means of the controller on the frame assembly of the vehicle.
[0008] Figure 3 exemplarily illustrates a magnified local side view of the controller along with the wiring harness, mounted on the frame assembly of the vehicle.
[0009] Figure 4 exemplarily illustrates a rear view of the vehicle. 5
DETAILED DESCRIPTION
[0001] With the developments of new features in an electric or hybrid vehicle, new parts or components are introduced, and it is often required to accommodate all 10 parts in a conventional layout. In electric vehicles and hybrid electric vehicle, a controller is located away from a power source and a motor. This results in energy losses and reduces the efficiency of the vehicle, and also increases the length of the wiring harness which is undesirable. Additionally, to maintain the driving efficiency and achieve good dynamic handling performance of the vehicle, a means 15 for cooling the controller is to be provided within a compact space. Apart from this, the center of gravity of the vehicle is to be maintained low, while packaging the heavy components like the motor, a battery, the controller, and the like to enable good maneuverability and agility of the vehicle as well as stability cum safety at various riding speeds. Therefore, there exists a need for a solution for packaging 20 the controller and other parts, which meets above challenges and overcomes limitations and compromises of known art.
[0002] Mounting layout for the controller in any vehicle is very critical, and should be located such that the distance of the controller from the motor and the battery does not affect the efficiency of the vehicle. An objective of the present subject 25 matter is to provide a secure, precise and robust location for the controller which is compact, reduces energy losses, maintains center of gravity, ensures efficient cooling, improves handling performance, ease of assembly as well as serviceability. The present subject matter is described using an exemplary two-wheeled electric vehicle, whereas the claimed subject matter is also applicable to a two-wheeled 30 hybrid electric vehicle, with required changes and without deviating from the scope
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of invention. In the present subject matter, a saddle-type vehicle includes a frame
assembly having a head tube and a controller. The frame assembly is defined by a
front frame region and a rear frame region. The front frame region includes a frame
front portion and a frame rear portion. The front portion extends rearwards from the
head tube, and the rear portion extends rearwards 5 and downwards from the front
portion. The front frame region extends rearwards from the head tube. The
controller is mounted on at least a portion of said rear portion.
[0003] As per an aspect of the present subject matter, the controller being disposed
above a battery housing and mounted on one or more of a left-side frame member
10 and a right-side frame member of the rear portion.
[0004] As per an aspect of the present subject matter, the controller is attached to
the right-side frame member of the rear portion.
[0005] As per an aspect of the present subject matter, the controller being
configured to be disposed substantially below a joining region. The joining region
15 joins the front portion to the rear portion of the frame assembly.
[0006] As per an aspect of the present subject matter, the joining region being
defined by an area below a rider seating having the frame assembly with one or
more portions extending substantially downwardly towards the ground.
[0007] As per an aspect of the present subject matter, the controller is additionally
20 mounted on a cross bracket connecting the right-side frame member and the leftside
frame member of the rear portion.
[0008] As per an aspect of the present subject matter, the controller is mounted on
one of the right-side frame members and the left-side frame members through a
plurality of affixing means e.g. bolts. The affixing means are made of metal and are
25 configured to transfer heat from said controller to the one of the right-side frame
member and the left-side frame member.
[0009] As per an aspect of the present subject matter, width of the battery housing
being substantially equal to the width of a footstep space of the vehicle.
[00010] As per an aspect of the present subject matter, a wiring harness from said
30 controller is connected to a battery. The battery connector is disposed in a front
4
frame region. The wiring harness from the controller is connected to a motor. The
motor is disposed in a rear frame region of the vehicle.
[00011] As per another aspect of the present subject matter, the controller includes
a holding bracket configured to guide and support said wiring harness.
[00012] As per another aspect of the present subject 5 matter, a vehicle comprises of
a controller, a battery housing, and a motor. The motor being encompassed by an
imaginary circle having a predetermined radius, when viewed from the side view
of the vehicle. The motor partially overlaps the controller and the battery housing,
when viewed from the rear of the vehicle.
10 [00013] As per another aspect of the present subject matter, a cumulative height of
the controller is encompassed by an imaginary cuboid. A battery housing is more
than twice the radius of imaginary circle encompassing the motor.
[00014] As per another aspect of the present subject matter, the controller being
configured to be positioned above the battery housing in a side view of the vehicle,
15 and a longitudinal portion of the controller at least partially overlaps a longitudinal
portion of the battery housing in a side view of the vehicle.
[00015] As per another aspect of the present subject matter, the motor is mounted
in a swingable manner and is configured to be laterally co-axial with a transmission
unit. The motor is disposed substantially rearward of the controller.
20 [00016] As per another aspect of the present subject matter, a drive axis of the
motor being disposed above an imaginary line. The imaginary line is formed by
joining an axis of a front wheel and a rear wheel.
[00017] As per another aspect of the present subject matter, the outer circumference
of the motor being determined by an imaginary circle of radius, the imaginary circle
25 encompassing the motor body. The imaginary circle at least partially overlaps the
imaginary line in a side view of the vehicle. The imaginary circle overlaps at least
a portion of the controller and a portion of the battery housing when seen in a rear
view of the vehicle. However, the present invention is not limited to the present
embodiments. The present subject matter is further described with reference to
30 accompanying figures. It should be noted that the description and figures merely
illustrate principles of the present subject matter. Various arrangements may be
5
devised that, although not explicitly described or shown herein, encompass the
principles of the present subject matter. Moreover, all statements herein reciting
principles, aspects, and examples of the present subject matter, as well as specific
examples thereof, are intended to encompass equivalents thereof.
[00018] Fig. 1(a) exemplarily illustrates a perspective 5 right side view of a twowheeled
electric vehicle 100 wherein the seat and side and other panels are omitted
for clarity. Fig. 1(b) exemplarily illustrates a perspective left side view of a twowheeled
electric vehicle 100. Said two-wheeled electric vehicle 100 includes a front
frame region (F), a rear frame region (R), a frame 101, a front wheel 105, a front
10 suspension unit 106, a rear wheel 107, a rear shock absorber 108, a transmission
unit 109 (shown in fig 1(b)), a controller 111, a battery housing 112, a motor 113,
and a battery connector 114.
[00019] The frame assembly 101 includes a head tube 102, a front portion 101(a),
a rear portion 101(b), a left-side frame member 104(a) (shown in fig 1(b)), and a
15 right-side frame member 104(b). The front portion 101(a) of the frame assembly
101 extends rearwards from the head tube 102 and the rear portion 101(b) extends
rearward and downwards from said front portion 101(a). The front portion 101(a)
and the rear portion 101(b) includes a left-side frame member 104(a) (shown in fig
1(b)) and a right-side frame member 104(b) running parallelly rearward and then
20 downward till the battery housing 112 of the vehicle 100. The front suspension unit
106 is supported by the head tube 102 at the upper end and lower end is supported
by the front wheel 105 in front frame region (F). The rear shock absorber 108 is
inclinedly disposed in the rear frame region (R) of the vehicle 100. The upper end
of the rear shock absorber 108 is supported by the rear portion 101(b) of the frame
25 assembly 101, and the lower end of the rear shock absorber 108 is supported by an
axle of the rear wheel 107, placed in the rear frame region (R) of the vehicle 100.
The transmission unit 109 (shown in fig 1(b)) is disposed in the rear frame region
(R) of the vehicle 100, and is supported by the rear wheel 107 at one end and by the
frame assembly 101 at the other end. The vehicle 100 includes the battery housing
30 112, disposed below the front portion 101(a) of the frame assembly 101 and extends
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horizontally rearward in vehicle longitudinal direction, till it reaches to connect
with the rear portion 101(b) of the frame assembly 101.
[00020] In the present embodiment, a battery (not shown) is placed inside the
battery housing 112 and said housing 112 acts as a floorboard of the vehicle 100.
The motor 113 is placed in the rear frame region 5 (R), disposed behind the rear
portion 101(b) of the frame assembly 101. The controller 111 of the vehicle 100 is
disposed between the left-side frame member 104(a) (shown in fig 1(b)) and the
right-side frame member 104(b) such that it is substantially below the joining
region (J) which joins the front portion 101(a) to the rear portion 101(b) of the
10 frame assembly 101. In the present embodiment, the controller 111 is mounted on
the right-side frame member 104(b). However, the controller 111 can be disposed
anywhere between the left-side 104(a) (shown in fig 1(b)) and the right-side frame
member 104(b). In another embodiment, the controller 111 is additionally mounted
on a cross bridge member 104(c) (shown in Fig 2(b)) disposed between the left side
15 frame member 104(a) (shown in fig 1(b)) and the right-side frame member 104(b).
In alternate embodiments, the controller 111 can be disposed on any type of frame,
such as sheet metal frames, tubular frames, and the like and configured to be
disposed substantially below the region (J) wherein region (J) is defined by
attachment of the front portion 101(a) of the frame assembly 101 is attached to the
20 rear portion 101(b) of the frame assembly 101. Alternatively, region (J) is defined
by the area below a rider seating (not shown) where the frame structure has one or
more portions extending substantially downwardly towards the ground.
[00021] The configuration of the controller 111 at this location facilitates in
increase of efficiency and reduces the losses of the vehicle 100 by minimising
25 wiring harness length and its transmission losses. The controller 111 is disposed
and packaged such that the controller 100 is near and in close vicinity to the battery
(not shown) as well as the motor 113. This placement also reduces length of wiring
harness 118 (shown in Fig 3) from the motor 113 to the controller 111 to give
maximum efficiency and to reduce the losses of the vehicle 100. The reduction in
30 wiring harness 118 reduces the cost of the wire, facilitates ease of routing during
assembly and serviceability of the vehicle 100. The controller 111 is disposed in
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the lower portion of the vehicle 100 which balances the centre of gravity of the
vehicle 100. The center of gravity of the vehicle 100 as per the present invention is
achieved to be substantially close to the lateral centre of the vehicle 100, and lower
in vertical direction from ground resulting in significant enhancement of handling
dynamics of the vehicle 100. To balance the centre 5 of gravity, the controller 111 is
placed as illustrated in the illustration shown in fig. 1(a) and (b).
[00022] Fig. 2(a) exemplarily illustrates a perspective front view of the mounting
means of the controller 111 on the frame assembly 101 of the vehicle 100. Fig. 2(b)
exemplarily illustrates a perspective rear view of the mounting means of the
10 controller 111 on the frame assembly 101 of the vehicle 100. In the present
embodiment, the controller 111 is mounted on the right-side frame member 104(b)
by means of a plurality of affixing means e.g. bolts 115. In the present embodiment,
the controller 111 is mounted using three-point mounting. Two mountings 116 are
provided on the upper portion of the right-side frame member 104(b) and one
15 mounting 117 is provided at the lower portion of the right-side frame member
104(b). However, the number of mounting points can be increased and decreased
to suit the requirements of the vehicle 100. The mounting points, apart from
mounting the controller 111, also facilitates in cooling of the controller 111. The
mounting points conducts the heat from the controller 111 to the frame assembly
20 101 and thus the heat is given away to the atmosphere, by way of conduction. So,
the contact between the controller 111 and the frame assembly 101 of the vehicle
100 is achieved by the mounting points to transfer the heat generated in the
controller 111 by natural cooling, without using any extra component. Apart from
this, the placement of the controller 111 on the right-side frame member 104(b),
25 creates additional adjacent space which can be utilized for disposing auxiliary
battery (not shown), or the space can be used as storage depending upon the vehicle
layout and requirements. The controller 111 has a predetermined size defined by
volume encompassed imaginary cuboid of width (CW), height (CH), and length
(CL).
30 [00023] Fig. 3 exemplarily illustrates a side view of the layout configuration of the
vehicle 100 as per the present invention and a magnified local side view of the
8
controller 111 along with the wiring harness 118, mounted on the frame assembly
101 of the vehicle 100. Fig. 4 exemplarily illustrates a rear view of the vehicle 100.
Fig.3 and fig.4 shall be discussed together. The controller 111 is disposed near the
battery (not shown) as well as the motor 113 of the vehicle 100. The battery (not
shown) is placed in the battery housing 112 and 5 the battery housing 112 acts as a
floorboard of the vehicle 100. The battery housing 112 has a predetermined length
(BHL) and a predetermined height (BHH). As per an embodiment, the battery
housing 112 width is substantially equal to the width of a footstep space (not shown)
of the vehicle 100. The battery connector 114 connects the battery (not shown) and
10 the controller 111 using the wiring harness 118. The battery connector 114 is
disposed above the battery housing 112, in the front frame region (F) of the vehicle
100. The layout of the vehicle controller 111, battery housing 112 and the motor
113 is configured such that an imaginary circle encompassing the motor 113 in a
side view defined by predetermined radius (Mr) at least partially overlaps both the
15 controller 111 as well as the battery housing 112 in a rear view of the vehicle 100
as shown in fig. 4. As per another aspect of the present invention, the cumulative
height of the controller 111 encompassing imaginary cuboid (CH) plus the battery
housing height (BHH) is more than twice the motor encompassing radius (Mr), CH
+ BBH > 2 x Mr. As per an aspect of the present invention, the controller 111 is
20 configured such that it is positioned above the battery housing 112 in a side view
of the vehicle 100 and the longitudinal portion of the controller (CL) (shown in fig.
2(b)) at least partially overlaps the longitudinal portion of the battery housing
(BHL) in a side view of the vehicle 100. The disposition of the controller 111 as
per the present invention and the battery connector 114 facilitates ease of assembly
25 of the wiring harness 118 and prevents any twisting or bending. The motor 113 is
disposed in the rear frame region (R) of the vehicle 100 and behind the rear portion
101(b) (shown in fig 1(b)) of the frame assembly 101. The wiring harness 118 from
the motor 113 to the controller 111 is guided by a holding bracket 119 to guide and
support the wiring harness 118. The holding bracket 119 restricts undesirable
30 movement of the wiring harness 118 and avoids short circuiting due to the contact
of the cables, at the motor 113 side. As per an aspect of the present invention, the
9
motor 113 is mounted in a swingable manner laterally co-axial with the
transmission unit 109 such that the motor 113 is disposed substantially rearward of
the controller 111. As per an aspect of the present layout the drive axis (Mx) of the
motor 113 is disposed above an imaginary line (FR) joining the axis of the front
wheel (Fwx) (shown in fig 1(a)) and the rear wheel 5 (Rwx) (shown in fig 1(a)). As
per an aspect of the present invention the motor 113 is disposed such that its outer
circumference determined by motor body encompassing radius (Mr) substantially
overlaps the imaginary line (FR) as well as the motor 113 simultaneously overlaps
at least a portion of the controller 111 and the battery housing 112 when seen in a
10 side view of the vehicle layout. Many other improvements and modifications may
be incorporated herein without deviating from the scope of the invention.
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20
25
10
List of Reference numerals:
100: Two-wheeled electric vehicle
F: Front frame region of 100
R: Rear frame region of 100
101: Frame assembly of 100 5
101 (a): front portion of 101
101(b): Rear portion of 101
102: Head tube
104 (a): Left-side frame member of 101(a)
104 (b): Right-side frame member of 101(a) 10
105: Front wheel of 100
106: Front suspension unit of 100
107: Rear wheel of 100
108: Rear shock absorber of 100
109: Transmission unit of 100 15
111: Controller of 100
112: Battery housing of battery
113: Motor of 100
114: Battery connector of battery
115: Affixing means of 111 20
116: Two mountings of 111
117: One mounting of 111
118: Wiring harness between 111 and 113
119: Holding bracket between 111 and 114
FR: Imaginary line ,CLAIMS:We claim:
1. A saddle-type vehicle (100) comprising:
a frame assembly (101) having a head tube (102);
wherein the frame assembly being defined by a front frame region (F) and a rear frame region (R); 5
wherein the front frame region (F) includes a frame front portion (101(a)) and a frame rear portion (101(b));
wherein the front portion (101(a)) extends rearwards from said head tube (102), and the rear portion (101(b)) extends rearwards and downwards from 10 said front portion (101(a)); and
wherein the front frame region (F) extends rearwards from the head tube (102); and
a controller;
characterized in that: 15
the controller (111) being mounted on at least a portion of said rear portion (101(b)).
2. The saddle-type vehicle (100) as claimed in claim 1, wherein the controller (111) being disposed above a battery housing (112) and mounted on one or 20 more of a left-side frame member (104(a)) and a right-side frame member (104(b)) of the rear portion (101(b)).
3. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller (111) is attached to the right-side frame member (104(b)) of the rear portion (101(b)). 25
4. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller (111) being configured to be disposed substantially below a joining region (J), said joining region (J) joins the front portion (101(a)) to the rear portion (101(b)) of the frame assembly (101).
2
5. The saddle-type vehicle (100) as claimed in claim 1, wherein said joining region (J) being defined by an area below a rider seating (not shown) having the frame assembly (101) with one or more portions extending substantially downwardly towards the ground.
6. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller 5 (111) being additionally mounted on a cross bracket (104(c)) connecting the right-side frame member (104(b)) and the left-side frame member (104(a)) of the rear portion (101(b)).
7. The vehicle (100) as claimed in claim 1, wherein said controller (111) being mounted on one of the right-side frame member (104(b)) and the left-side 10 frame member (104(a)) through a plurality of affixing means (115), said affixing means (115) are made of metal and are configured to transfer heat from said controller (111) to the one of the right-side frame member (104(b)) and the left-side frame member (104(a)).
8. The vehicle (100) as claimed in claim 1, wherein width of said battery 15 housing (112) being substantially equal to the width of a footstep space (not shown) of the vehicle (100).
9. The vehicle (100) as claimed in claim 1,
wherein a wiring harness (118) from said controller (111) being connected to a battery connector (114); 20
wherein the battery connector (114) being disposed in a front frame region (F); and
wherein the wiring harness (118) from said controller (111) being connected to a motor (113);
wherein the motor (113) being disposed in a rear frame 25 region (R) of the vehicle (100).
10. The vehicle (100) as claimed in claim 9, wherein said controller (111) includes a holding bracket (119) configured to guide and support said wiring harness (118).
3
11. A vehicle (100) comprising:
a controller (100);
a battery housing (112); and
a motor (113);
Characterized in that: 5
said motor (113) being encompassed by an imaginary circle having a predetermined radius (Mr), when viewed from the side view of the vehicle (100); and
said motor (113) partially overlaps the controller (111) and the battery housing (112), when viewed from the rear of the vehicle. 10
12. The vehicle (100) as claimed in claim 11,
wherein
a cumulative height of the controller (111),
said controller (111) being encompassed by an imaginary cuboid (CH); and 15
a battery housing (BHH) being more than twice the radius Mr of imaginary circle encompassing the motor (113).
13. The vehicle (100) as claimed in claim 11, wherein said controller (111) being configured to be positioned above the battery housing (112) in a side view of the vehicle (100) and a longitudinal portion of the controller (CL) 20 at least partially overlaps a longitudinal portion of the battery housing (BHL) in a side view of the vehicle (100).
14. The vehicle (100) as claimed in claim 11, wherein said motor (113) being mounted in a swingable manner and being configured to be laterally co-axial with a transmission unit (109), said motor (113) being disposed 25 substantially rearward of the controller (111).
15. The vehicle (100) as claimed in claim 11, wherein a drive axis (not shown) of the motor (113) being disposed above an imaginary line (FR) wherein said imaginary line (FR) being formed by joining an axis of a front wheel (Fwx) and a rear wheel (Rwx). 30
4
16. The vehicle (100) as claimed in claim 11, wherein the outer circumference
of said motor (113) being determined by an imaginary circle of radius (Mr),
said imaginary circle encompassing the motor body; and
wherein said imaginary circle at least partially overlaps the imaginary
line (FR) in a side view of the vehicle, and 5 wherein said imaginary circle
overlaps at least a portion of the controller (111) and a portion of the battery
housing (112) when seen in a rear view of the vehicle (100).