Claims:I/We claim:
1. A vehicle (100) comprising:
a controller assembly (110) comprising:
a controller (500) having a plurality of first set of screw bores;
a controller tray (410) having a plurality of second set of screw bores wherein said controller (500) mounted on said controller tray (410) through a first set of mounting fasteners (720a) affixed through each of the respective first set of screw bores and the second set of screw bores; and
a mounting bracket (710) having a plurality of third set of screw bores fastened to a cooling assembly (420) through a second set of mounting fasteners (720b), wherein said mounting bracket (710) being attached to said controller tray (410);
wherein said controller assembly (110) being disposed centrally below a seat assembly (330) in the rear cabin of said vehicle (100) adjacent to a motor (210).
2. The vehicle (100) as claimed in claim 1, wherein said controller (500) is attached to a plurality of cooling fins (510).
3. The vehicle (100) as claimed in claim 1, wherein said controller assembly (110) disposed below said seat assembly (330) through a controller cut-out (320).
4. The vehicle (100) as claimed in claim 1, wherein said controller assembly (110) being securely locked through a controller lock cover (310).
5. The vehicle (100) as claimed in claim 1, wherein said cooling assembly (420) directs outside air and blows the air to said plurality of cooling fins (510) attached to said controller assembly (500) based on a temperature sensing means.
6. The vehicle (100) as claimed in claim 1, wherein said cooling assembly (420) can be at least one of a cooling fan, a radiator fan, and a blower.
7. A controller tray (410) for a controller assembly (110) of a vehicle comprising:
a vertically-elongated first arm (410a) extending outwardly, having a plurality of second set of screw bores, wherein one end of said first arm (410a) being readily releasably affixed to a controller (500) with a plurality of first set of screw bores; wherein each of said screw bores of said first arm (410a) is screwed into respective screw bores of said controller (500) through a first set of mounting fasteners (720a) for securing said controller (500);
a vertically-elongated second arm (410b) extending outwardly, having a plurality of second set of screw bores, wherein free end of said second arm (410b) being readily releasably affixed to said controller (500) with a plurality of first set of screw bores; wherein each of said screw bores of said second arm (410b) is screwed into respective screw bores of said controller (500), through a second set of mounting fasteners (720b) for securing said controller (500); and
a tray bracket member (415) having a hollow cavity, a plurality of screw bores, an upper surface and a lower surface;
wherein the upper surface of said tray bracket member (415) being provided with means for securely affixing to the fixed ends of said first arm (720a) and said second arm (720b);
wherein the lower surface of said tray bracket member (415) being provided with the plurality of second set of screw bores for securely attaching to a mounting bracket (710).

8. A mounting bracket (710) for a controller assembly (110) of a vehicle comprising:
a mounting pad (715) with a hollow cavity including at least one ear located at both side surfaces and a plurality of third set of screw bores made in said mounting pad (715) to fasten with respective screw bores in a cooling assembly (420) through a second set of mounting fasteners (720b); and
a protruding first arm (725a) on at least one side of said mounting pad (715) with the plurality of third set of screw bores coupled with a controller tray (410) though a second set of mounting fasteners (720b); and
a protruding second arm (725b) on at least one side of said mounting pad (715) with the plurality of third set of screw bores coupled with said controller tray (410) through the second set of mounting fasteners (720b);

wherein said cooling device (420) fits in the hollow cavity of the mounting pad (715) and is operatively configured to direct outside air to a plurality of cooling fins (510) in said controller assembly (110) based on a temperature sensing means.
, Description:TECHNICAL FIELD
[0001] The present subject matter generally relates to a motor controller for an electric vehicle, and, more particularly to an air-cooling assembly connected for the motor controller.

BACKGROUND
[0002] Generally, the conversion of the conventional petrol-diesel three-wheeled vehicle to an electric vehicle involves removing the entire internal combustion engine from the vehicle, installing the electric motor in its place, and also adding a large bank of batteries. In a known electric three-wheeled vehicle, a basic layout for an EV is tuned with different size motors, batteries, and a motor controller for each motor and batteries, wheels and suspension.
[0003] Typically, in an electric vehicle, the powertrain consists of an electric machine, a motor controller, a battery pack, and an overall vehicle controller. Generally, the motor controller in the electric vehicle operates between the batteries and the motor to control the electric vehicle’s speed and acceleration similar to a carburetor in a gasoline-powered vehicle.
[0004] The motor controller achieves the said operation with the help of the instructions of the gear, the throttle and the brake, to control the running state of the electric vehicle including various operations such as starting operation, speed, climbing strength, as well as braking mechanism. Thus, it is employed to regulate the torque generated by the motors of electric vehicles by means of modifying the energy flow from the power sources to the motor. Further, it transforms the battery’s direct current into alternating current (for AC motors only) and regulates the energy flow from the battery. The motor controller is further configured to reverse the motor rotation (so the vehicle can go in reverse), and convert the motor to a generator (so that the kinetic energy of motion can be used to recharge the battery in the form of regenerative braking when the brake is applied).

BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The detailed description is described with reference to an embodiment of a three wheeled multi-track vehicle along with the accompanying figures. In the figures, similar numbers are used throughout to reference like features and components.
[0006] Fig. 1 illustrates a schematic side view of a vehicle, in accordance with an embodiment of the present subject matter.
[0007] Fig. 2 illustrates an upper perspective view of the vehicle, in accordance with an embodiment of the present subject matter.
[0008] Fig. 3 depicts a schematic side view of a controller lock cover and controller cut-out, in accordance with an embodiment of the present subject matter.
[0009] Fig. 4 depicts an enlarged view of the position of a controller assembly and the various components in the vehicle, in accordance with an embodiment of the present subject matter.
[00010] Fig. 5 illustrates an enlarged view of various components of the controller assembly, in accordance with an embodiment of the present subject matter.
[00011] Fig. 6 (a) illustrates an enlarged perspective view of the vehicle locating the position of the controller assembly in the vehicle, in accordance with an embodiment of the present subject matter.
[00012] Fig. 6 (b) illustrates an enlarged perspective view of the vehicle locating the position of a controller tray, in accordance with an embodiment of the present subject matter.
[00013] Fig. 7 (a) illustrates an exploded view of various components of the controller assembly, in accordance with an embodiment of the present subject matter.
[00014] Fig. 7 (b) depicts the operation of flow of air in the controller assembly, in accordance with an embodiment of the present subject matter.
[00015] Fig. 8 (a) illustrates an enlarged front perspective view of the controller assembly, in accordance with an embodiment of the present subject matter.
[00016] Fig 8 (b) illustrates an isometric sectional side view of the controller assembly, in accordance with an embodiment of the present subject matter.
[00017] Fig. 8 (c) illustrates another isometric back view of the controller assembly, in accordance with an embodiment of the present subject matter.
[00018] Fig. 9 (a) depicts an enlarged view of a controller tray, in accordance with an embodiment of the present subject matter.
[00019] Fig. 9 (b) depicts an enlarged view of a mounting bracket, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION
[00020] Typically, the motor controller is used to control the rate of charge using information from the battery. Moreover, the controller translates pressure on the accelerator pedal to adjust speed in the motor inverter. Once a request for power is sent to the vehicle controller, the vehicle controller in turn communicates with the motor controller. The motor controller then requests DC (Direct current) power from the battery pack. The DC power is then inverted into AC (Alternating current) electric power for the motor.
[00021] During the above-mentioned operations performed by the motor controller, the temperature of the motor controller should be maintained in an acceptable range at all times by vehicle controller to limit vehicle controller power. The temperature of the motor controller is monitored to prevent any of these components from being damaged by exceeding its maximum operating temperature. The magnitude of heat energy depends on the operating conditions, power and current demand, of the motor controller.
[00022] Exemplary embodiments detailing features of the three-wheeled vehicle, in accordance with the present invention will be described hereunder. The embodiments described herein apply to an electric three-wheeled vehicle powered by a drive motor. However, the present invention is not restricted in its application and is also applicable to vehicles employing an internal combustion engine or either by an internal combustion engine or the drive motor selectively or by the drive motor alone.
[00023] The three-wheeled automotive vehicle is mainly, but not solely, used as a passenger carrier. It is to be noted that “front” and “rear”, and “left” and “right” wherever referred to in the ensuing description, refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the vehicle and looking forward. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers generally to a side to side, or left to right axis relative to the vehicle. Various other features of the three-wheeled vehicle according to the present subject matter here will be discernible from the following further description thereof, set out hereunder.
[00024] Fig. 1 shows a schematic side perspective view of an exemplary three-wheeled vehicle (100) (hereinafter “vehicle’) with few parts omitted for clarity. As per one embodiment, the vehicle, referenced by the numeral (100), powered by an electric motor (not shown). The vehicle (100) can be used as a passenger carrier vehicle or a load carrier vehicle. It has a front cowl (105) supporting a windscreen (not shown). As per one embodiment, the lower portion of the front cowl (105) is connected to a front wheel (115) with a wheel cover (120) disposed in between. A pair of left and right front light assembly (125) disposed on the front cowl (105) of the vehicle (100). A handlebar assembly (305) (shown in Fig. 3) is present behind the front cowl (105) which is used to operate the vehicle (100). As per one embodiment of the present invention, a floor panel (130) is extending from the bottom portion of the front cowl (105) to the rearward direction of the vehicle (100), supported by a vehicle frame assembly (135). In one embodiment, the vehicle (100) is divided into two compartments along the line X-Y, a driver compartment (D) having a driver’s seat assembly (not shown) in a front portion (F) of the vehicle (100) and a passenger compartment (P) having at least one passenger seat assembly (shown in Fig. 3) in a rear portion (R) of the vehicle (100). In one embodiment, said pair of rear wheels (140) are connected to a swing arm (145) through one or more rear suspension (150). The rear suspension includes a shock absorber and a suspension spring unit mounted to the vehicle frame assembly (135).
[00025] Further, in one embodiment, at least one pillar structure (155) including a first pillar structure (155a) and a second pillar structure (155b) projects upwardly from opposite sides of said floor panel (130) and a partition wall (160) extends transversely between said first pillar structure (155a) and said second pillar structure (155b) and further separates said driver compartment (D) from said passenger compartment (P). As per one embodiment of the present invention, the rear portion (R) along with the passenger compartment (P) of the vehicle (100) is supported on a pair of rear wheels (140) located on either side of the longitudinal axis (AA) of the vehicle (100).
[00026] According to one embodiment of the present invention, a pair of side rails (165a, 165b) extends longitudinally between the front portion (F) and the rear portion (R) of the vehicle frame assembly (135). The rear portion (R) of said the vehicle frame assembly (135) comprises of said pair of side rails (165a, 165b) extending upwardly from opposite sides of the front portion (F) of the vehicle frame assembly (135) and further terminating rearwardly along the longitudinal axis of the vehicle (100).
[00027] As per one embodiment of the present invention, the vehicle frame assembly (135) is a semi-monocoque frame assembly (135) having a ladder like tubular frame structure. The ladder like tubular frame structure of the vehicle frame assembly (135) comprises of said pair of side rails (165a, 165b) extending longitudinally from the front portion (F) to the rear portion (R) of the vehicle frame assembly (135). The front portion (F) comprises of the floor panel (130) being rigidly secured to said at least some portion of said pair of side rails (165a, 165b) and extends along a longitudinal axis of said vehicle (100).
[00028] In one embodiment, a rear portion of the vehicle frame assembly (135) includes a pair of side rails (165a, 165b) laterally spaced by one or more cross-members (170) along a vehicle transverse axis. As per one embodiment of the present invention, said at least one passenger seat assembly (shown in Fig. 3) is disposed on said rear portion (R) of the vehicle (100). In one of the embodiments of the present invention a controller assembly (110) is disposed in the rear portion (R) of the vehicle (100). The controller assembly (110) controls the electric vehicle’s speed and acceleration. The controller assembly (110) is employed to regulate the torque generated by a motor (not shown) of the vehicle (100) by means of modifying the energy flow from the power sources to the motor. As per an embodiment of the present invention, the controller assembly (110) is connected to the one or more cross members (170) of the vehicle frame assembly (135) via connecting means such as fasteners, welding, etc. According to an embodiment of the present invention the controller assembly (110) is positioned substantially in the center of the one or more cross members (170) along a vehicle transverse axis.
[00029] Fig. 2 illustrates a top view of the vehicle (100), in accordance with an embodiment of the present subject matter. As per an embodiment of the present subject matter the controller assembly (110) is disposed behind an auxiliary battery assembly (205) when seen along the longitudinal axis from the front end of the vehicle (100). According to an embodiment of the present invention the controller assembly (110) is positioned in front of the motor (210) and a transmission assembly (not shown), when seen along the longitudinal axis from the front end of the vehicle (100). As per an embodiment of the present invention, the controller assembly (110) is disposed in close vicinity to the motor (210), this enables reduction in the wiring length required for connecting the controller (110) to the motor (210). According to an embodiment of the present invention, the motor (210), power electronics, and transmission assembly (not shown) can be combined to form one compact unit.
[00030] Fig. 3 illustrates a schematic side view of a controller lock cover and controller cut-out, in accordance with an embodiment of the present subject matter. According to an embodiment of the present invention the controller assembly (110) is disposed centrally along a vehicle transverse axis, below the passenger seat assembly (330) on said rear portion (R) of the vehicle (100). In one of the embodiments of the present invention the controller assembly (110) is accessible via a controller cut out (320) provided at the top wall (T) of the passenger seat assembly (330). As per an embodiment of the present invention, the controller cut-out (320) is disposed centrally along a vehicle transverse axis, on the top wall (T) of the seat assembly (330) substantially in-line with the controller assembly (110). This ensures that the controller assembly (110) is easily accessible for servicing through the controller cut-out (320) provided right below the seat (not shown) of the passenger seat assembly (330).
[00031] Fig. 4 illustrates an enlarged view of the position of the controller assembly (110) and the various components in the vehicle (100), in accordance with an embodiment of the present subject matter. As per an embodiment of the present invention the controller assembly (110) has a controller (500) (shown in Fig. 5) mounted on a controller tray (410). According to an embodiment of the present invention the controller tray (410) is connected to the one or more cross members (170) (shown in Fig. 1 and Fig. 2) of the vehicle frame assembly (135) via connecting means such as fasteners, welding, etc. In one of the embodiment of the present invention, a cooling assembly (420) is attached to the controller tray (410) through a mounting means. In one embodiment of the present invention, said cooling assembly (420) can be at least one of a cooling fan, a radiator fan, and a blower. As per an embodiment of the present invention, the mounting means can be a mounting bracket (not shown). The controller (500) (shown in Fig. 5) of the vehicle (100) functions by utilizing a potentiometer; supplying a certain amount of voltage from the batteries to the motor (210). This action generates a huge amount of heat due to the internal resistance of the controller (500). In order for the vehicle (100) to operate at optimum condition, temperature of the controller (500) has to be maintained at a certain limit. Hence, the cooling system (420) is required to enable the efficient cooling of the controller assembly (110). The cooling assembly (420) plays a crucial role towards achieving better heat removal rate from the controller assembly (110).
[00032] Fig. 5 illustrates an enlarged view of various components of the controller assembly (110), in accordance with an embodiment of the present subject matter. As per an aspect of the present invention, the controller assembly (110) includes the controller (500), the controller tray (410) wherein the controller (500) is mounted on the controller tray (410); and the cooling assembly (420) attached to the controller tray (410) through the plurality of mounting means. As per an embodiment of the present invention, a plurality of cooling fins (510) are connected to the controller (500). As per an embodiment of the present invention, the controller tray (410) has a plurality of vertically-elongated arms (410a, 410b) extending outwardly, having a plurality of screw bores (not shown). In one of the embodiment of the present invention a free end of the plurality of arms (410a, 410b) being readily releasably affixed to the controller (500). In one embodiment, the controller tray (410) has a tray bracket member (415). According to an embodiment of the present invention, the plurality of vertically-elongated arms (410a, 410b) extending outwardly are attached to the tray bracket member (415). As per an embodiment the tray bracket member (415) is rectangular in shape. In one of the embodiment the tray bracket member (415) can be square, rhomboidal and other parallelograms, trapezoidal in shape. As per an embodiment of the present invention, the other end of the plurality of arms (410a, 410b) of the controller tray (410) is connected to the one or more cross members (170) (shown in Fig. 1 and Fig. 2) of the vehicle frame assembly (135) via connecting means such as fasteners, welding, etc.
[00033] According to an aspect of the present invention, the cooling assembly (420) directs outside air and blows the air to the plurality of cooling fins (510) attached to the controller assembly (110) based on a temperature sensing means (not shown). As per an aspect of the present invention, the cooling assembly (420) is positioned to directly face the plurality of cooling fins (510) in order to provide efficient cooling of the controller (500) at pre-determined intervals.
[00034] Fig. 6 (a) illustrates a top-view of the frame assembly (135) of the vehicle (100) locating the position of the controller assembly (110) in the vehicle (110), in accordance with an embodiment of the present subject matter. As per an embodiment of the present invention, the controller assembly (110) is positioned centrally below a passenger seat (330) (shown in Fig. 3) in the rear portion of the vehicle frame assembly (135) on one or more cross-members (170) along a vehicle transverse axis. According to an embodiment of the present invention, the cross member (170) is disposed between the pair of side rails (165a, 165b) extending longitudinally between the front portion (F) and the rear portion (R) of the vehicle frame assembly (135). Fig. 6 (b) illustrates a side-view of the frame assembly (135) of the vehicle (100) locating the position of the controller tray (410), in accordance with an embodiment of the present subject matter.
[00035] Fig. 7 (a) illustrates an exploded view of various components of the controller assembly (110), in accordance with an embodiment of the present subject matter. According to an embodiment of the present invention, the controller assembly (110) includes the controller (500) having a plurality of first set of screw bores, the controller tray (410) having a plurality of second set of screw bores. According to an embodiment of the present invention, the controller (500) is mounted on the controller tray (410) through a first set of mounting fasteners (720a) affixed through each of the respective first set of screw bores and the second set of screw bores. As per an embodiment of the present invention, the mounting bracket (710) having a plurality of third set of screw bores being fastened to the cooling assembly (420) through a second set of mounting fasteners (720b). The cooling assembly (420) enables effective heat dissipation and thus, prevents the temperature rise of electronic components to exceed allowable values and reduce the absolute performance. As per an embodiment of the present invention, the mounting bracket (710) is attached to the controller tray (140). In one embodiment of the present invention, the controller (110) is attached to the set of cooling fins (510).
[00036] According to an embodiment of the present invention, the mounting bracket (710) for a controller assembly (110) has a mounting pad (715) with a hollow cavity including at least one ear located at both side surfaces and a plurality of third set of screw bores made in the mounting pad (715) to fasten with respective screw bores in the cooling assembly (420) through a second set of mounting fasteners (720b). As per an embodiment of the present invention, a protruding first arm (725a) is disposed on at least one side of the mounting pad (715) with the plurality of third set of screw bores coupled with the controller tray (410) though a second set of mounting fasteners (720b). In one embodiment, a protruding second arm (725b) is disposed on at least one side of the mounting pad (715) with the plurality of third set of screw bores coupled with the controller tray (410) through the second set of mounting fasteners (720b). According to an embodiment of the present invention, the cooling assembly (420) fits in the hollow cavity of the mounting pad (715) and is operatively configured to direct outside air to the set of cooling fins (510) in the controller (500) based on a temperature sensing means.
[00037] Fig. 7 (b) illustrates the operation of flow of air in the controller assembly (110), in accordance with an embodiment of the present subject matter. As per an embodiment of the present invention, the cooling assembly (420) directs the outside air towards the cooling fins (510) in the controller (500). According to an embodiment of the present invention, the outside air coming from the cooling assembly (420) is directed towards the cooling fins (510) having high thermal conductivity. The cooling fins (510) increase the surface area that air coming from the cooling assembly (420) can act on. Hence, maximum cooling efficiency can be achieved. As per an embodiment of the present invention, the cooling assembly (420) is removable attached to the controller tray (410) using the mounting bracket (710). As per an embodiment of the present invention, the cooling assembly (420) is attached to the mounting bracket (710) by the second set of mounting fasteners (720b) through the tray bracket member (415). The controller assembly (110) is accessible via the controller cut-out (320) at the top wall (T) of the seat assembly (330) (shown in Fig. 3).
[00038] Fig. 8 (a) illustrates an enlarged front view of the controller assembly (110), in accordance with an embodiment of the present subject matter. Fig 8 (b) illustrates an isometric sectional side view of the controller assembly (110), in accordance with an embodiment of the present subject matter. Fig. 8 (c) illustrates another isometric back view of the controller assembly (110), in accordance with an embodiment of the present subject matter.
[00039] Fig. 9 (a) depicts an enlarged perspective view of the controller tray (410), in accordance with an embodiment of the present subject matter. Fig. 9 (b) depicts an enlarged view of the mounting bracket (710), in accordance with an embodiment of the present subject matter.
[00040] The vehicle (100) includes, but not limited to, at least one of an electric vehicle and a hybrid vehicle. The vehicle (100) includes, but not limited to, at least one of a two-wheeler vehicle, a three-wheeler vehicle and a four-wheeler vehicle.
[00041] As per an embodiment of the present invention, the vehicle (100) is at least in one of a stationary mode and mobile mode.
[00042] According to the above assembly, the primary efficacy of the present invention is that the controller assembly is easily of accessible through a service window, i.e. controller cut-out provided below the seat assembly in the passenger compartment of the vehicle. Thus, the controller is safe and at the same time can be easily accessed for servicing through the controller cutout without making any major modifications in the vehicle component layout.
[00043] According to above assembly, the second efficacy of the present invention is that the cooling assembly covers 80 percent of the cooling fins face. This leads to better cooling efficiency. Hence, above invention provides simple and cost-effective cooling solution.

List of reference signs:

100 vehicle
110 controller assembly
210 motor
310 controller lock cover
320 controller cut-out
330 seat assembly
410 controller tray
410a first arm
410b second arm
415 tray bracket member
420 cooling device
500 controller
510 set of cooling fins
610 chassis
710 mounting bracket
715 mounting pad
720a first set of mounting fasteners
720b second set of mounting fasteners
725a protruding first arm
725b protruding second arm