DESC:FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
A SMART MODULAR AND INTEGRATED POWERTRAIN SYSTEM FOR BATTERY ELECTRIC VEHICLES

2. APPLICANT(S):
a) Applicant Name: Ozone Motors Private Limited
b) Nationality: Indian
c) Address: RTBI IITM Research park, Kanagam road,
Taramani, Chennai 600113
INDIA.

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

4. DESCRIPTION

Technical Field of Invention

The present invention relates to a smart modular and integrated powertrain system for battery electric vehicle.
Background of the Invention

A powertrain is the primary propulsion system used in a vehicle. It helps in propelling the vehicle forward on the ground. Powertrain is responsible to transmit mechanical power generated by a motor or engine to the wheels, that moves the vehicle on the ground but not limited to the kind of vehicle or application.

Indian patent application number 201644035271 discloses a powertrain mount assembly for a motor vehicle. The power train includes a resilient mount that is connected to a powertrain component by a connecting arm. The resilient mount is moveable by an actuator member.

Indian patent application number 201641021237 discloses a hybrid powertrain for vehicles. The powertrains are fitted in parallel manner. The powertrain disclosed is retrofittable.

Indian patent application number 201641016346 discloses a hybrid vehicle powertrain having an induction motor. The hybrid vehicle powertrain includes a synchronous generator configured to control the induction motor by regulating the voltage output of said induction motor.

In the prior-art literature, powertrain consists of only the electric motor and controller coupled with a transmission along with a differential system, and in some cases a hybrid system with a combustion engine as well. However, the problem with the existing powertrains are they are not smart enough to protect the users and the powertrains have no communication capabilities and no user interface for interaction and management. Also, these powertrains are not packaged to have all crucial components that an electric vehicle needs and can make use of considering an end product.

In the prior-art literature, certain artworks also have issues in insulation, while others fail due to high jolting and during regular operation of the vehicles. Also, some high voltage systems do not have efficient cooling techniques that contributes to lower energy efficiency in the entire powertrain.

Another problem found in the prior art literature is that the modularity of the system is not found, since there needs to be fresh architecture designed for various application and the systems are not scalable due to other constraints like lack of room for extra components and risk of lowering the energy efficiency.

Therefore, there is a need of a smart modular and integrated powertrain system to improve the energy efficiency of an electric vehicle, maintain high safety standards for users in case of an incident, enabled with communication system that helps the manufacturers and users to get critical information about the system and sub systems and stay informed.

Brief Summary of the Invention

The following summary provides an introduction to selected concepts in a simplified form that 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 be used as an aid in determining the scope of the claimed subject matter. Further, while certain disadvantages of other technologies may be noted or discussed herein, the claimed subject matter is not intended to be limited to implementations that may solve or address any or all of the disadvantages of those other technologies. The sole purpose of this Summary is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed description that is presented below.

An object of the present invention is to provide a smart modular and integrated powertrain for electric vehicles that is safer than the existing inventions and also makes it easier for vehicle makers to adopt and easily implement the system in to their products.

Another object of the present invention is to provide a system with a housings and assembly to ensure all the components of the smart modular and integrated powertrain are safely and effectively mounted on the system with perfect fits and low friction among moving parts ensuring no physical damage to the components during accidents, fire, thermal breach and short circuits or electrical damages.

Another object of the present invention is a transmission system with reduction gears & differential drive for specified automobile applications. Which transmits mechanical energy to the wheels of the vehicle.

Another object of the invention is system with a high efficiency bus bar connection between the motor and the primary driver / controller terminals, and other sub systems to ensure lower energy transmission losses, also durable industrial connectors for power and data transmission

Another object of the invention is system with an efficient and active air/liquid cooling system to ensure the operating temperature is within prescribed limits to ensure higher energy efficiency of the system.

Another object of the invention is a system which is power distribution system that includes DC/DC converters of HV to LV, offering an output of not limited to 12V, 5V & 3.3 V respectively for other peripheral systems, which is enabled with isolation circuit. The power from the 12 V system has two uses, including but not limited to power the 12V systems and also charge the auxiliary battery of the vehicle.

Another object of the invention is a system which is a high voltage circuit breaker mechanism which isolated the battery pack form the powertrain in case of physical accidents or thermal breach.

Another object of the invention is a system which is an accelerometer & gyroscope that can measure the vibrations and G-Forces acting on the powertrain and can predict the isolation of circuit during an accident or impact.

Another object of the invention is a system which is an array of temperature sensors that can measure the temperature of the critical components mentioned in the first object which is a smart modular and integrated powertrain for battery electric vehicles to ensure the components are working in the stipulated operating temperature to ensure high efficiency of each system/component by actuating the cooling system as mentioned in the previous object. Also helps in detection of thermal breach of systems.

Another object of the invention is a system that has a location sensing module which continuously monitor the location of the same.

Another object of the invention is a system that has a GSM module that collects the data based on the priority and sends to an assigned server with in a stipulated interval of time.

Another object of the invention is a system that has a CAN interface receiver & transmitter that collected CAN data from other parts or systems of the vehicle and sends to respective modules for further analysis.

Another object of the invention is a system which is a microcontroller that collects data from all the subsystems, analyse the same to ensure all the systems are working as per a predefined protocol.

Another object of the invention is a system that has a firmware that collects, manages and monitors the data used in the entire system. Which is capable of over the air update.

Yet another object of the invention is a system which is an electrical Vacuum pump for power brakes of the vehicle.

Yet another object of the invention is a system which is an electrical A/C compressor for the HVAC of the vehicle.

Yet another object of the invention is a system which includes all cooling system peripherals including but not limited to an electrical cooling pump, coolant hose, non-return valves, radiators and radiator fans.

According to an aspect of the present invention, a smart modular and integrated powertrain system for battery electric vehicle is disclosed. A smart modular and integrated powertrain system for battery electric vehicle includes a housing assembly that can accommodate and mount multiple components that are not limited to electric motor, primary motor drive or controller, and an integrated power transmission system with differential component, peripheral power distribution circuit including DC/DC converter circuits, AC Compressor, Vacuum pump for brakes, cooling system with pump, master control unit and various sensors and modules. The present invention provides safe mounting, effective operation of moving parts with low friction and also prevents the components from vibration from the vehicle and also protects limited electrical and electronic components from physical damage, short circuiting and limited protection from water and dust.

According to an aspect of the present invention, the smart modular and integrated powertrain system further comprises a bus bar and automobile grade connectors that connects the terminals and transmits electricity to the electric motor from the primary driver or controller. The system transmits power from the primary EV driver to the DC/DC converter and also connects the battery power to the primary EV drive

According to an aspect of the present invention, the system has a transmission system with an array of reduction gears & differential drive for specified automobile applications which transmits mechanical energy to the wheels of the vehicle.

According to an aspect of the present invention, the system has a high efficiency bus bar connection between the motor and the primary driver / controller terminals, and other sub systems to ensure lower energy transmission losses, also durable industrial connectors for power and data transmission

According to an aspect of the present invention, the system includes an active air/liquid cooling system to ensure the operating temperature of the sub systems inside the housing.

According to an aspect of the present invention, the system includes a power distribution system that is a DC/DC converter of HV to LV offering an output of 12V, 5V & 3.3V respectively. The power from the 12 V system has two uses, including but not limited to power the 12V systems and also charge the auxiliary battery of the vehicle.

According to an aspect of the present invention, the system includes a high voltage circuit breaker mechanism which isolated the battery pack form the powertrain in case of physical accidents or thermal breach

According to an aspect of the present invention, the system includes an accelerometer & gyroscope that can measure the vibrations and G-Forces acting on the powertrain and can predict the isolation of circuit during an accident or impact.

According to an aspect of the present invention, the system includes an array of temperature sensors that can measure the temperature of the critical components mentioned in the first object which is a smart modular and integrated powertrain for battery electric vehicles to ensure the components are working in the stipulated operating temperature to ensure high efficiency of each system/component by actuating the cooling system as mentioned in the previous object. Also helps in detection of thermal breach of systems.

According to an aspect of the present invention, the system includes a location sensing module which continuously monitor the location of the same.

According to an aspect of the present invention, the system includes a GSM module that collects the data based on the priority and sends to an assigned server with in a stipulated interval of time

According to an aspect of the present invention, the system includes a CAN interface receiver & transmitter that collected CAN data from other parts or systems of the vehicle and sends to respective modules for further analysis

According to an aspect of the present invention, the system includes a microcontroller that collects data from all the subsystems, analyse the same to ensure all the systems are working as per a predefined protocol.

According to an aspect of the present invention, the system includes a firmware that collects, manages and monitors the data used in the entire system. Which is capable of over the air update

According to an aspect of the present invention, the system includes an electrical Vacuum pump for power brakes of the vehicle

According to an aspect of the present invention, the system includes an electrical A/C compressor for the HVAC of the vehicle

According to an aspect of the present invention, the system includes all cooling system peripherals including but not limited to an electrical cooling pump, coolant hose, non-return valves, radiators and radiator fans.

According to an aspect of the present invention, the smart modular and integrated powertrain system further comprises a master contactor/breaker that disconnects the power of the system entirely in case of an emergency like accident or thermal breach, which is controlled by a microcontroller that monitors the powertrain using multiple sensors.

According to an aspect of the present invention, the cooling system is either air cooled or liquid cooled system with forced cooling capabilities in the liquid cooled system

According to an aspect of the present invention, the system comprises of a vacuum pump & A/C compressor as peripheral units for the ease of plug & play of vehicle manufacturers.

According to an aspect of the present invention, the microcontroller has a firmware that is capable of updating itself over the air.

According to an aspect of the present invention, wherein the microcontroller has capabilities to communicate with an external server using https or equivalent communication protocol, also has an internal CAN communication protocol.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the present invention are illustrated by accompanying drawings, wherein:

FIG. 1 illustrates the powertrain housing that are inter connected and accommodates the electric motor, motor controller and transmission gears with differential drive, and other peripheral systems according to an embodiment of the invention;

FIG. 2 illustrates the high efficiency bus bars for high voltage and durable industrial connectors used for power and data transmission of the powertrain entirely according to an embodiment of the invention;

FIG. 3 illustrates the essential control unit for EV drive according to an embodiment of the invention;

FIG. 4 illustrates the safety cut off system for an EV drive which isolates the battery form the powertrain in case of emergency according to an embodiment of the invention;

FIG. 5 illustrates the in-built DC/DC converter which supplies multiple DC voltages for other systems and components according to an embodiment of the invention;

FIG. 6 illustrates the in-built location sensing & GSM module along with the micro controller of the powertrain which has a firmware that enables inter system CAN & cloud HTTPS communication protocols;

FIG. 7 illustrate side view and top view of the air-cooled controller housing for low voltage system according to an embodiment of the invention;

FIG. 8 illustrates liquid cooled controller housing for high voltage system according to an embodiment of the invention.

Detailed Description of the Invention

It is to be understood that the present disclosure is not limited in its application to the details of composition set forth in the following description. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 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 item.
Reference throughout this specification to “one embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “one embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, different embodiments, or component parts of the same or different illustrated invention.
Each statement of an embodiment is to be considered independent of any other statement of an embodiment despite any use of similar or identical language characterizing each embodiment. The wording “one embodiment”, or the like, does not appear at the beginning of every sentence in the specification, is merely a convenience for the reader’s clarity. However, it is the intention of this application to incorporate by reference the phrasing “an embodiment,” and the like, at the beginning of every sentence herein where logically possible and appropriate.

A smart modular and integrated powertrain system for battery electric vehicles is disclosed.

According to one embodiment of the invention, the system includes a bus bar that connects the terminals and transmits electricity to the electric motor from the primary driver or controller ensuring lower energy loss in transmission.

According to one embodiment of the invention, the system includes an array of temperature sensors to collect data and support in monitoring the temperature of the motor, primary driver, and other selected peripheral components which shall enable the master controller to disconnect the high voltage system in case of a thermal breach or accident. The system also includes a master breaker that disconnects the power of the system entirely in case of an incident like, short circuit, physical damage, accident or fire. Further, the system also comprises air and liquid cooling mechanism based on the application and usage to maintain the operating temperature, thereby improving the efficiency of the entire powertrain.

Further, the system includes a master control unit connected with multiple sensors and a dedicated firmware/software that enables the system to be smart by operating, managing and monitoring the entire powertrain and its sub systems functions. Which is capable of over the air update

According to one embodiment of the invention, the master control unit shall have an active internet connection and communication protocol that ensures the system software stays updated and connected with servers all time sending in critical and essential information for the manufacturers and users as well. The system may have a touch user interface for the users to have access to information, also to control and communicate with the system entirely, making it easy to use for users.

Referring to figures, FIG. 1 illustrates the powertrain housing that are inter connected and accommodates the electric motor, motor controller and transmission gears with differential drive, and other peripheral systems according to an embodiment of the invention. 1A is the master housing that carries all sub housings and components including the motor housing 1H, controller housing 1C, peripheral mounting 1E, A/C compressor 1F, Vacuum pump 1G and the water pump 8E of the smart powertrain ensuring physical and vibrational protection for all the components; in the system the master housing has a mounting area 1B that provides damping of the vibration and shall be connected to the sub frame of the vehicle. It is designed to be plug and play with universal shear mount capabilities. The housing 1A also accommodates the transmission gears 1D with perfect fit and tolerance providing smooth and efficient transmission, the master housing 1A also has a cavity to carry the transmission oil/fluid in it to ensure optimal lubrication and maintenance of temperature during all operating conditions; 1C represents the first sub housing that carries the electrical and electronics components of the smart powertrain including the electric vehicle (EV) drive unit 3A & 3B, the DC/DC converter 5A, contactor 4A and the connectors 2A, 2B, 2C & 2D; the housing 1I us used to enclose the bus bar connectors 2A that connects to the motor 1H & controller 1C; the system also has a motor housing 1H that is connected to the master housing 1A using screw bolts; 1E serves as a mounting bracket that mounts the A/C compressor 1F, vacuum pump 1G & water pump 8E with the master housing

FIG. 2 illustrates the high efficiency bus bars for high voltage and durable industrial connectors used for power and data transmission of the powertrain entirely. FIG. 2 is the exploded view of the sub housing 1C which accommodates the components as mentioned in the aforementioned paragraph. The system has a high efficiency bus bar connectors 2A that transmits power inside the housing 1C including the power connection from the battery terminals 2B to the controller drive 3A, power connection form the EV drive 3A to the DC/DC converter 5A, also power from the EV drive 3A to the motor 1H. The system also includes two high power connector plug 2B that is automobile industrial grade which received power from the battery using appropriate receptacles; the system also includes industrial grade low power output connectors 2C that supplied 12V &5V to other peripheral system; the system also includes a 32Pin communication & low power connector 2C which is also industrial grade and connects to the external sensors and other communication systems outside the smart EV powertrain.

FIG. 3 illustrates the essential control unit for EV drive which includes the circuit board with power electronics 3A that is firmly mounted to the lower part of the housing ensuring very low or no vibration is acting on the control board of the EV drive. The system also has inbuilt temperature sensors 3B to monitor the temperature of the board that communicates with the microcontroller 6C for diagnostics purposes.

FIG. 4 illustrates the safety cut off system for an EV drive which isolates the battery form the powertrain in case of emergency the contactor 4A is controlled by the microcontroller 6C during emergency to cut off the power to the EV drive 3A during emergency situations such as thermal breach, accidents etc.

FIG. 5 illustrates the in-built DC/DC converter which supplies multiple DC voltages for other systems and components; the system includes a DC/Dc multi-channel converter 5A that receives high voltage from the EV drive board 3A using bus bard 2A and converts it to low voltage of 12V which is supplied for peripheral system via connector 2C, also the 5V & 3.3V supply is supplied to the control board 6A for other systems and peripherals.

FIG. 6 illustrates the in-built location sensing & GSM module along with the micro controller of the powertrain which has a firmware that enables inter system CAN & cloud HTTPS communication protocols; the system includes the control board 6A that accommodates the multiple sensors like Accelerometer & gyroscope of the ev powertrain, the microcontroller 6C, location sensor, and the GSM module of the smart EV powertrain. The system 6A is mounted on the EV drive 3C making it as a subsystem of the EV drive 3A. The system also has a GSM connector 6B that connects to the external GSM antenna, the connector is generic and any GSM antenna can be used for connectivity. The system 6C is capable of multiple communication protocols and also has a firmware inside it which ensures the monitoring, management of multiple subsystems and sensors in the smart EV powertrain that includes but are not limited to data collection, analysis & decision making and data transmission.

FIG. 7 illustrates isometric view of the air cooled controller housing for low voltage system according to an embodiment of the invention; the system includes the air cooled lid 7A of the sub housing 1C, which has external fins for heat dissipation; the system also includes the lid of the motor 1H which has an air cooled lid 7B & 7C respectively of different fin heights to ensure effective cooling during diverse ambient applications. The system uses the 7B fins for high performance applications where as the 7C short fins for the nominal performance applications of the motor and the powertrain

FIG. 8 illustrates liquid cooled controller housing for high voltage system according to an embodiment of the invention; the system includes the copper cooling tubes 8A of the sub housing 1H with a lid 8B. The system ensures proper flow of coolant fluid through the surface of the motor ensuring optimal temperature is maintained for its continual use. The system also includes the copper cooling tubes 8C of the sub housing 1C with a lid 8D. The system ensures proper flow of coolant fluid through the surface of the controller housing ensuring optimal temperature is maintained for its continual use; the system also includes a coolant pump/water pump 8E that pumps the cooled fluid in and sucks the hot fluid out of the cooling tubes 8A & 8C. The pump 8E is controlled by the microcontroller 6C which monitors the temperature of the motor and controller continuously.

The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the present invention will become more fully apparent from the following description and appended claims or may be learned by the practice of the invention as set forth hereinafter.
,CLAIMS:5. CLAIMS
I/WE CLAIM

1. A smart modular and integrated powertrain system for battery electric vehicles, the smart modular and integrated powertrain system comprising:
a housing assembly to accommodate and mount multiple sub housing and components including electric motor, primary motor drive or controller;
a differential component & transmission system;
at least one DC/DC converter circuit;
an AC Compressor pump;
a vacuum pump for brakes;
a cooling system with pump;
a master control unit and various sensors including but not limited to temperature sensors, accelerometer & gyroscope, location sensors; and a
a communication module.

2. The smart modular and integrated powertrain system as claimed in claim 1, wherein the smart modular and integrated powertrain system further comprises a bus bar and automobile grade connectors that connects the terminals and transmits electricity to the electric motor from the primary driver or controller.

3. The smart modular and integrated powertrain system as claimed in claim 1, wherein the smart modular and integrated powertrain system further comprises array of temperature sensors to collect data and support in monitoring the temperature of the motor, primary driver, and other selected peripheral components.

4. The smart modular and integrated powertrain system as claimed in claim 1, wherein the smart modular and integrated powertrain system further comprises a master contactor/breaker that disconnects the power of the system entirely in case of an emergency like accident or thermal breach, which is controlled by a microcontroller that monitors the powertrain using multiple sensors.

5. The smart modular and integrated powertrain system as claimed in claim 1, wherein the cooling system is either air cooled or liquid cooled system with forced cooling capabilities in the liquid cooled system.

6. The smart modular and integrated powertrain system as claimed in claim 1, wherein the system comprises of a vacuum pump & A/C compressor as peripheral units for the ease of plug & play of vehicle manufacturers.

7. The smart modular and integrated powertrain system as claimed in claim 1, wherein the microcontroller has a firmware that is capable of updating itself over the air.

8. The smart modular and integrated powertrain system as claimed in claim 1, wherein the microcontroller has capabilities to communicate with an external server using https or equivalent communication protocol, also has an internal CAN communication protocol.

6. DATE AND SIGNATURE

Anugu Vijaya Bhaskar Reddy
Dated this 23rd of February 2019