Claims:1. A vehicle (100) comprising:
a front portion (F) defining a front frame structure (102(a)) and a rear portion (R) defining a rear frame structure (102(b));
said rear frame structure (102(b)) includes a left rear frame member (101(a)) and a right rear frame member (101(b)), the left rear frame member (101(a)) being disposed parallel to the right rear frame member (101(b)) at the rear portion (R);
a sub frame assembly (107) disposed in the rear portion (R) supported with the rear frame structure (102(b));
wherein, the sub frame assembly (107) is disposed between the left rear frame member (101(a)) and the right rear frame member (101(b)); and
wherein a first region (108) of said sub frame assembly (107) is configured to support a power unit (110) and a second region (109) of said sub frame assembly (107) is configured to support a transmission unit (111) of said vehicle (100).

2. The vehicle (100) as claimed in claim 1, wherein said first region (108) and said second region (109) are substantially orthogonal to each other to enable orthogonal assembly and dis-assembly of the sub frame assembly (107).

3. The vehicle (100) as claimed in claim 1, wherein said first region (108) and said second region (109) are so formed such that the members forming both regions are attached to the left rear frame member (101(a)) and the right rear frame member (101(b)) through a rear bridge member (115).

4. The vehicle (100) as claimed in claim 1, wherein said first region (108) is formed by a pair of side members (113) attached to a front member (114), said pair of side members (113) and the front member (114) are attached to the rear bridge member (115) to form a structure for placing a power unit (110) on top of the structure so formed.

5. The vehicle (100) as claimed in claim 4, wherein the power unit (110) disposed in said first region (108) and enclosed in a locking structure (131(a)), said locking structure (131(a)) includes a top holding bracket (132), one or more base plate (133), one or more bottom stopper plate (134) and one or more side mounting rods (135).

6. The vehicle (100) as claimed in claim 1, wherein said second region (109) is formed by a pair of downward members (118) and a bottom member (119), said pair of downward members (118) extend downwards from said rear bridge member (115).

7. The vehicle (100) as claimed in claim 6, wherein at least one of said pair of downwards members (118) is disposed offset to a center portion of the rear bridge member (115) to create a space on a second half for mounting other parts of the vehicle (100).

8. The vehicle (100) as claimed in claim 6, wherein said bottom member (119) is configured to be attached to a lowermost end of the pair of downward members (118), said bottom member (119) extends laterally beyond the pair of downward members (118) on both sides.

9. The vehicle (100) as claimed in claim 8, wherein said bottom member (119) is configured to have a plurality of mounting brackets, said plurality of mounting brackets (123) are configured to receive one or more damper unit (127) as a motor mounting point and as a gear box mounting point.

10. The vehicle (100) as claimed in claim 1, wherein the transmission unit (111) includes a gear box (111(b)) coupled with a motor (111(a)), the gear box (111(b)) includes an extended mounting provision (124) on a rear lower portion, and a front mounting provision (126) disposed at a front side, and the motor (111(a)) includes an upward extending member (125) on a side portion, the extended mounting provision (124), the front mounting provision (126) and the upward extending member (125) being configured to mount the transmission unit (111) to the subframe assembly (107).

11. A sub frame assembly (107) comprising:
a power unit (110);
a transmission unit (111); and
one or more electrical system (not shown);
said power unit (110), said transmission unit (111), and said one or more electrical system (not shown) are disposed on said sub frame assembly (107) to form a single unit;
wherein the direction of assembly and dis-assembly of said power unit (110), said transmission unit (111), and said one or more electrical system (not shown) are in a substantially orthogonal direction to each other.

12. The sub frame assembly (107) as claimed in claim 11, wherein said power unit (110) is disposed above said transmission unit (111) and one or more electrical system (not shown). , Description:TECHNICAL FIELD
[0001] The present subject matter relates generally to a vehicle, and more particularly but not exclusively relates to a sub frame assembly for the vehicle.

BACKGROUND
[0002] Generally, in internal combustion engine powered vehicles, an engine along with a transmission unit and a gear box unit drives the vehicle. In hybrid vehicles, the traction system includes the engine with the transmission unit, the gear box and a motor powered by a battery. Similarly, in electric vehicle, the traction system includes the motor along with the transmission unit and the gear box with differential unit for a multitrack vehicle. Mostly, the motor is mounted on the solid axle transmission unit. With an increasing demand of the compact multitrack vehicles with high functionality, particularly for compact electric and hybrid vehicle, the packaging layout of the vehicles is extensively explored and been worked upon.

BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The details are described with reference to an embodiment of a three wheeled autorickshaw along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components. Figure 1 exemplarily illustrates a perspective view of three-wheeled vehicle.
[0004] Figure 2(a) exemplarily illustrates a rear view of a sub frame assembly having a power unit and a transmission unit.
[0005] Figure 2 (b) exemplarily illustrates a side view of the sub frame assembly having the power unit and the transmission unit.
[0006] Figure 3 exemplarily illustrates an exploded view of the sub frame assembly with the power unit, transmission unit, and other electrical components.
[0007] Figure 4 exemplarily illustrates a sub frame assembly.
[0008] Figure 5 (a) exemplarily illustrates the transmission unit with the mounting mechanism.
[0009] Figure 5 (b) exemplarily illustrates the transmission unit mounted on the sub frame assembly.
[00010] Figure 6 exemplarily illustrates the power unit of the vehicle.

DETAILED DESCRIPTION

[0001] With the developments of new features in an electric vehicle, new parts or components are introduced, and it is often required to accommodate all parts in a conventional layout. Alternatively, there is a need for manufacturer to have a standard platform layout of vehicle which can cater to variety of powertrains like IC engine, EV, Hybrid etc. based on markets and customer requirements. In conventional vehicles, a motor is placed from the top side of the vehicle along with a gear box, but this way of positioning the motor and the gear box along with a power unit is cumbersome. The increase in number of parts or components makes the compact packaging of the vehicle, a challenging task. In addition to this, increase in number of parts results in increase of assembly time in assembly line and thus makes the entire assembly process difficult and time consuming. Therefore, there exists a need for an improved solution for assembling a transmission unit having the motor and the gear box along with the power unit and other related parts in the vehicle, which overcomes above problems and other problems of known art.
[0002] Mounting layout for the transmission unit and the power unit in any vehicle is very critical, and should be capable of holding the transmission unit and the power unit with stability, precise alignment as well as dampen the vibrations and noises produced within the vehicle to provide smooth handling of the vehicle and greater rider comfort. An objective of the present subject matter is to provide a secure, precise and robust frame assembly which is compact, light in weight and simple with less assembly time in the assembly line. The present subject matter is described using an exemplary three-wheeled electric vehicle, whereas the claimed subject matter is applicable to a three as well as four-wheeled vehicles, with required changes and without deviating from the scope of invention. In the present subject matter, a vehicle has a front portion defining a front frame structure and a rear portion defining a rear frame structure. The left rear frame member being disposed parallel to the right rear frame member at the rear portion of the vehicle. A sub frame assembly disposed in the rear portion is supported with the rear frame structure. The sub frame assembly is disposed between the left rear frame member and the right rear frame member. A first region of the sub frame assembly is configured to support a power unit and a second region of the sub frame assembly is configured to support a transmission unit of the vehicle.
[0003] As per an aspect of the present subject matter, the first region and said second region are substantially orthogonal to each other to enable orthogonal assembly and dis-assembly of the sub frame assembly.
[0004] As per an aspect of the present subject matter, the power unit is a battery and the transmission unit includes a motor coupled with a gear box. The first region and the second region are attached to the left rear frame member and the right rear frame member through a rear bridge member.
[0005] As per an aspect of the present subject matter, the first region includes a pair of side members attached to a front member. The pair of side member and the front member are attached to the rear bridge member to form a structure for placing the power unit on top of the structure so formed.
[0006] As per an aspect of the present subject matter, the power unit disposed in the first region is enclosed in a locking structure. The locking structure includes a top holding bracket, one or more base plate, one or more bottom stopper plate and one or more side mounting rods.
[0007] As per another aspect of the present subject matter, the second region includes a pair of downward members and a bottom member. The pair of downward members extend downwards from the rear bridge member. At least one of said pair of downwards members is disposed offset to a center portion of the rear bridge member. The bottom member is configured to be attached to a lowermost end of the pair of downward members. The bottom member extends beyond the pair of downward members on both sides.
[0008] As per another aspect of the present subject matter, the bottom member is configured to have a plurality of mounting brackets. The plurality of mounting brackets are configured to receive one or more damper unit as a motor mounting point and as a gear box mounting point. A rear lower portion of the gear box has an extended mounting provision and a side portion of the motor has an upward extending member for ease of assembly with the bottom member.
[0009] As per another aspect of the present subject matter, the sub frame assembly includes the power unit, the transmission unit, and the one or more electrical system. The power unit, said transmission unit, and said one or more electrical system are disposed on said sub frame assembly to form a single unit. The direction of assembly and dis-assembly of said power unit, said transmission unit, and said one or more electrical system are in a substantially orthogonal direction to each other. The power unit is disposed above said transmission unit and one or more electrical system. The embodiments of the present invention will now be described in detail with reference to an embodiment in a three wheeled electric vehicle along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be 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.
[00010] Fig. 1 exemplarily illustrates a perspective partial exploded view of a three-wheeled vehicle 100 wherein the roof and rear cover of the three-wheeled vehicle 100 is omitted for clarity. Said three-wheeled electric vehicle 100 includes a front portion (F), a rear portion (R), a left rear frame member 101(a), a right rear frame member 101(b), a center bridge member 103, a sub frame assembly 107, a middle partition 104, a front wheel 105, and a pair of rear wheels (one wheel shown) 106. The front portion (F) defining a front frame structure (not shown) and the rear portion (R) defining a rear frame structure 102(b). The rear frame structure 102(b) includes the left rear frame member 101(a) and the right rear frame member 101(b) disposed parallel to each other. The center bridge member 103 is disposed between the left rear frame member 101(a) and right rear frame member 101(b) configured to support the rear frame structure 102(b) ahead of the sub frame assembly 107. The front wheel 105 is disposed in the front portion (F) of the vehicle 100 and a pair of rear wheels (one wheel shown) 106 is disposed at the rear portion (R) of the vehicle 100. The sub frame assembly 107 disposed in the rear portion (R) is supported with the rear frame members (101(a), 101(b)). The sub frame assembly 107 is disposed between the left rear frame member 101(a) and the right rear frame member 101(b). A first region (not shown in this fig.) of the sub frame assembly 107 is configured to support a power unit 110 and a second region (not shown in this fig.) of the sub frame assembly 107 is configured to support a transmission unit 111 of the vehicle 100.
[00011] Fig. 2(a) exemplarily illustrates a rear view of the sub frame assembly 107 having the power unit 110 and the transmission unit 111. Fig. 2(b) exemplarily illustrates a side view of the sub frame assembly 107 having the power unit 110 and the transmission unit 111. In the present embodiment, the sub frame assembly 107 includes a first region 108 and a second region 109. The first region 108 is placed in vehicle forward-rearward direction and is configured to support the power unit 110 of the vehicle 100. The second region 109 is positioned at substantially right angle in downward direction with respect to the first region 108 of the sub frame assembly 107. The second region 109 is configured to support the transmission unit 111 of the vehicle 100. The transmission unit 111 includes the motor 111 (a) and the gear box 111(b). A first face 112(a) of the power unit 110 is directed in the vehicle forward direction whereas a second face 112(b) of the power unit 110 is directed towards the cabin tail door (not shown) at the rear portion (R) of the vehicle 100.
[00012] Fig. 3 exemplarily illustrates an exploded view of the sub frame assembly 107 with the power unit 110, transmission unit 111, and peripheral electrical components. The power unit 110 is placed in the first region 108 from the top of the sub frame assembly 107. The transmission unit 111 is placed in the second region 109 from sideways and the peripheral electrical components are placed on the sub frame assembly 107 at the distal end of the sub frame assembly 107 of the vehicle 100. In the present embodiment, the electrical component placed on the sub frame assembly 107 is a DC-DC converter 128. The transmission unit 111 is disposed at one side of the second region 109 of the sub frame assembly 107, creating adjacent space for accommodating any electrical components or other parts of the vehicle 100. In the present subject matter, the DC-DC converter 128 is placed in the adjacent space. The entire sub frame assembly 107 is welded together to form a single unit. This reduces the assembly time of the respective parts in the assembly line. The power unit 110, the transmission unit 111, and the DC-DC converter 128 are placed on the sub frame assembly 107 to form a single unit wherein the direction of assembly and dis-assembly of each of them is in a substantially orthogonal direction to each other.
[00013] Fig.4 exemplarily illustrates perspective view of a sub frame assembly 107. The sub frame assembly 107 includes the first region 108 and the second region 109. The first region 108 is formed by a pair of side members 113 attached to a front member 114, forming a H-shaped structure. The pair of side members 113 and the front member 114 are attached to the rear bridge member 115 for placing the power unit (not shown) on top of the structure, so formed. The structure so formed is disposed on the vehicle frame with the help of a plurality of mounting points 116. In the present embodiment, four mounting points 116 are provided for mounting the members forming the first region 108 on the vehicle frame. Two mountings are provided at the end side of the pair of side members 113 and other two mountings are provided at the rear bridge member 115. The four mounting points 116 are provided with a guiding member 116(a) for guiding a fastening means (not shown). In the present subject matter as per an embodiment, the guiding member 116(a) is cylindrical in shape and is made up of steel material. This guiding member 116 (a) acts as a stiffening member and provides strength to the mounting points 116 and the sub frame assembly 107 of the vehicle, by restricting the movement of the fastening means (not shown) and keeping them at their designated place. In addition to this, as per an additional embodiment, a plurality of L-shaped first stiffener 117 is attached at the inside corners of the structure, formed by attaching the rear bridge member 115, the pair of side members 113, and the front member 114. This L-shaped first stiffener 117 provides strength to the first region 108 and distributes the load evenly on the sub frame assembly 107 of the vehicle.
[00014] The second region 109 of the sub frame assembly 107 includes a pair of downward members 118 and a bottom member 119. The pair of downward members 118 extends downwards from said rear bridge member 115. The pair of downward members 118 are disposed on a side of the rear bridge member 115 to create a space on the other side, for mounting other parts or components of the vehicle. The bottom member 119 is configured to be attached to a lowermost end of the pair of downward members 118, the bottom member 119 extends beyond the pair of downward members 118 on both sides. As per an embodiment, the pair of downward members 118 and the bottom member 119 are tubular in shape, which facilitates in ease of mounting of the second region 109 with the first region 108. However, the shape of the pair of downward members 118 and the bottom member 119 can be different, depending upon the requirements and design of the vehicle layout. The bottom member 119 is configured to have a plurality of mounting brackets 123 to mount the transmission unit 111. The one or more members forming the second region 109 of the sub frame assembly 107 is configured to have a plurality of structural support members. A pair of first support member 120 is disposed with the pair of downward members 118 on the rear side of the rear bridge member 115, providing structural support and strength to hold the transmission unit 111. A pair of second support member 121 is placed below the pair of first support member 120, circumscribing the pair of downward members 118 and is supported by the rear bridge member 115. The pair of second support member 121 provides strength to the second region 109 and avoids twisting of the profile of the second region 109 of the sub frame assembly 107. The pair of third support member 122 is a coupling member attached to the connecting portion of the pair of downwards tube 118 and the bottom member 119. The pair of third support member 122 provides a rib type support to the second region 109 of the sub frame assembly 107. The pair of downward members 118 are disposed on the side of the rear bridge member 115 to create a space on the other side for mounting other parts or components of the vehicle. As per an aspect of the present invention, the first and second regions (108, 109) are disposed substantially orthogonally with each other. Additionally, a first bracket 129 is provided on the rear bridge member 115 at the other side of the pair of downward members 118 to mount electrical parts or any other components.
[00015] Fig. 5(a) exemplarily illustrates the perspective view of the transmission unit 111 with the mounting mechanism. Fig. 5(b) exemplarily illustrates perspective view of the transmission unit 111 mounted on the sub frame assembly 107. The transmission unit 111 includes the motor 111(a) and the gear box 111(b), provided with three mounting points. A rear lower portion of the gear box 111(b) is configured to have a mounting point, which is an extended mounting provision 124. In the present embodiment, the extended mounting provision 124 is a tube structure, bend at its upper end to be mounted on the bottom member 119. However, the shape of the extended mounting provision 124 can be different based on the requirements and design of the gear box 111(b). A side portion of the motor 111(a) is configured to have a second mounting point for ease of assembly. An upward extending member 125 is provided at the side of the motor 111(a) with an extended arm to mount on the bottom member 119. A front mounting provision 126 is disposed at the front side of the gear box 111(b) to mount the transmission unit 111 at the front side. As shown in fig. 5(b), the extended mounting provision 124 and the upward extending member 125 are used to mount the gear box 111 (a) and motor 111(b) assembly on the bottom member 119 of the sub frame assembly 107 assembled from a lateral direction of the vehicle. The extended mounting provision 124 and the upward extending member 125 are mounted with the help of one or more damper unit 127. The damper unit 127 dampens the noise and vibrations produced by the transmission unit 111, while in operation and restricts the vibration from transmitting to the vehicle body, ensuring rider comfort. The extended mounting provision 124, the front mounting provision 126 and the upward extending member 125 being configured to mount the transmission unit 111 to the subframe assembly 107. In the present embodiment, the space created adjacent to the pair of downward tube 118 is utilized to mount the DC-DC converter 128 in a direction orthogonal to the mounting direction of the transmission unit 111. The first bracket 129 is fixed on the rear side of the rear bridge member 115 to mount the converter 128. As per an embodiment, the DC-DC converter 128 is provided with a second bracket 130, which is mounted on the first bracket 129. This configuration allows other types of converter to be mounted on the rear bridge member 115 through the first bracket 129 without changing the mounting mechanism as the first bracket 129 acts as a compatible mounting bracket for all types of electrical components.
[00016] Fig. 6 exemplarily illustrates the power unit 110 of the vehicle. The power unit 110 of the vehicle is disposed on the top side of the first region 108 of the sub frame assembly 107 assembled from the top direction substantially orthogonal to the direction of assembly of the transmission unit 111 and electrical unit e.g. DC-DC convertor 128. The power unit 110 includes one or more battery set 131, depending on the power requirement of the vehicle. The power unit 110 is enclosed in a locking structure 131(a). The locking structure 131(a) includes a top holding bracket 132, one or more base plate 133, one or more bottom stopper plate 134 and one or more side mounting rods 135. The power unit 110 rests on the one or more base plate 133 of the locking structure 131(a). The base plate 133 has a partial U-shaped structure. This U-shaped base plate facilitates the accommodation of nut and bolt disposed in the depression of U-shape, and thus allows the power unit 110 to be disposed on the base plate 133. In the present embodiment, one of the legs of one of the U-shaped base plate 133 extends in the upward direction to restricts the movement of the power unit 110 from the front side of the vehicle. The side stopper plate 134 is a L-shaped structure and is disposed at the bottom portion of the power unit 110 on both the sides. This restricts the sideways movement of the power unit 110. In the present embodiment, one side of the stopper plate 134 is made fixed by means of welding or other similar process and the other side of the stopper plate 134 is made as an adjustable plate. During vehicle operation, there is a possibility of the battery set 131 to get loosened because of the vibration and stress produced in the vehicle. So, one of the stopper plates 134 is made adjustable so as to adjust the battery set 131 to make it a compact and tighten the packaging to avoid slippage.
[00017] The mounting rods 135 are placed at both the sides of the power unit 110. The mounting rod 135 is inserted in the stopper plate 134 to take support on both the sides. The top holding bracket 132 is mounted on the top of the power unit 110 and is connected to the mounting rods 135 on both the sides through a plurality of fastening means 136. A second stiffener 137 is disposed at the middle part of the top holding bracket 132. The second stiffener 137 avoids any deformation and bending of the top holding bracket 132 while operation of the vehicle or while tightening of the fastening means 136. A cushioning member 138 is placed between one or more battery set 131 to avoid contact so as to restrict wearing out of the casing. The cushioning member 138 is also disposed between the top of the power unit 110 and the top holding bracket 132. The cushioning member 138 is also placed between the sides of the power unit 110 and the one or more stopper plates 134. In an embodiment, the cushioning member 138 is 4 to 5 mm thick. The cushioning member 138 arrests the metal to metal contact and facilitates more grip between the parts to avoid slippage. Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of Reference numerals:
100: Three-wheeled vehicle
F: Front portion of 100
R: Rear portion of 100
101 (a): Left rear frame member of 102 (b)
101(b): Right rear frame member of 102 (b)
102 (a): Front frame structure of F
102 (b): Rear frame structure of R
103: Center bridge member of 102 (b)
104: Middle partition of 100
105: Front wheel of 100
106: Pair of rear wheels of 100
107: Sub frame assembly of 102(b)
108: First region of 107
109: Second region of 107
110: Power unit of 100
111: Transmission unit of 100
111 (a): Motor of 111
111 (b): Gear box of 111
112 (a): First face of 110
112 (b): Second face of 110
113: Pair of side members of 108
114: Front member of 108
115: Rear bridge member of 108
116: Plurality of mounting points of 108
116(a): Guiding member of 116
117: L-shaped first stiffener of 108
118: Pair of downward members of 109
119: Bottom member of 109
120: Pair of first support member of 109
121: Pair of second support member of 109
122: Pair of third support member of 109
123: Plurality of mounting brackets on 119
124: Extended mounting provision of 111(b)
125: Upward extending member
126: Front mounting provision of 111(b)
127: Damper unit on 119
128: DC-DC converter of 100
129: First bracket of 128
130: Second bracket of 128
131: One or more battery set of 110
131 (a): Locking structure of 110
132: Top holding bracket of 110
133: One or more base plate of 110
134: One or more stopper plate of 110
135: One or more side mounting rods of 110
136: Fastening means of 135
137: second stiffener of 132
138: Cushioning member of 110