DESC:FIELD OF INVENTON
This invention relates to a motor and controller system of an automotive vehicle. More particularly this invention relates to design of cooling system for a motor and controller of an automotive vehicle.

BACKGROUD OF THE INVENTION
Most of the automotive vehicles used for the transportation of human and goods are powered by internal combustion engines. There are many disadvantages to using internal combustion engines. It emits exhaust gases, which lead to pollution of the atmosphere. These engines have a number of moving parts. These engines generate more heat during the combustion process. Hence, these engines are not efficient and environment friendly.
Now a days, people prefer electric motors to power vehicles instead of internal combustion engines. These are less polluting and have a lower number of moving parts as compared with IC engines. Hence, the electric motors are more efficient than IC engines. A vehicle having an electric motor as a power unit to drive, it is normally called an electric vehicle (EV).
The electric vehicle mainly comprises an electric motor to drive the vehicle, batteries to supply power to the electric motor, and a controller to regulate the power supplied to the motor from the batteries. Normally, the electric motor and controller are mounted separately and at distance between them. The cost of the system is increased due to the separate mounting arrangements of the motor and controller Due to the greater distance between motor and controller, there is always a packaging related issue as both have to be packaged separately. Individual packaging necessitates additional wire length required to make between them, which increases the likelihood of wire cut and power failure, hence call for a safe routing and protection. Extra wire length also increases the power losses during power transmission. The wires consumes reasonable space in the vehicle thus making it difficult to accommodate other components of vehicles.
To solve the above issue, some prior arts have adopted motor and controller as one unit, wherein the controller is mounted on the motor's rear side or on top of the motor (Refer figure 6). However in such arrangements, the major issues faced is thermal management of the controller and motor, because, normally, the controller works at a 70-degree centigrade temperature and the motor works at a 120-degree centigrade temperature. Here, the temperature of the controller increases due to the transfer of heat from the motor to the controller by conduction or convection, and/or radiation. This leads to malfunctioning and reduced life of Controller. Hence, these prior arts faced a lot of challenges in adopting the integral motor and controller method. In electric vehicle applications, efficiency, cost, and reliability are important parameters, and that’s why this concept of integral design is not used frequently.
Some prior arts disclose use of liquid cooled motors and controllers to address thermal issues, however these concepts are expensive and are larger/bulky in size. For compact electric vehicles (for ex. 2-wheeler, 3-wheeler, and small 4-wheeler), liquid cooled design is not feasible due to cost and size.

OBJECT OF THE INVENTION
The object of the invention is to solve the abovementioned problems of the automotive vehicle. More particularly, the object of the invention is to provide an automotive vehicle with a cooling system that effectively cools the motor as well as the controller of the vehicle.

Another object of the invention is to design a mounting arrangement of the motor and controller which reduces the heat transfer from the motor to the controller.

Another object of the invention is to design a mounting arrangement of the motor and controller which reduces the length of connecting wires used between motor and controller and occupy minimum space in the vehicle.

Another object of the invention is to design a cooling system for the motor and controller of an automotive vehicle that is cost-effective and increases the efficiency of the system.

SUMMARY OF INVENTION
To avoid the problems mentioned above and achieve the objects, the applicant developed a cooling system for an integrated motor and controller, wherein it comprises:
a) A fan,
b) A shroud,
c) A diffuser,
d) A connector,
Wherein;

I. The motor, controller and fan are arranged co-axially in the axial direction of the motor shaft.
II. The controller is thermally isolated and mounted on the motor with a heat resistant connector (to avoid heat transfer from the motor to the controller),
III. A fan is mounted on the motor shaft and arranged between the motor and the controller.
IV. The motor and controller are both cooled by the said fan.
V. A shroud is disposed around the motor, fan, and controller.
VI. The shroud has a varying cross section, particularly minimum diameter at the portion disposed around the fan.
VII. A deflector is provided on the shroud at a minimum diameter location towards the controller side.

The fan is an axial fan which is rotated in the direction such that the atmospheric air is sucked from the controller side. Because of the shape created by the shroud's reduced diameter and the deflector attached to the shroud, air is deflected towards the fan's centre. This sucked air cools the controller while travelling over it in the gap between the shroud and the controller and through the fins of the controller. Furthermore, the air is thrown towards the motor by the rotation of the fan. The air is guided over the motor and flows in the gap between the shroud and the motor and through the fins of the motor, thus cooling the motor more efficiently before exiting from the other end.

The air drawn in by the fan is at ambient temperature. It flows over the controller, which is at a moderately high temperature (for example, 70 °C). The sucked air cools the controller while the temperature of the air increases moderately. This air flows over the motor, which is at a high temperature (for example, 120 °C). This air is relatively cool as compared to the motor temperature. Therefore, it cools the motor while being guided over it and exits at a high temperature from the other end of the motor. Thus, a single fan is used to cool both the motor and the controller effectively.

The controller is arranged in the axial direction of motor near the fan side of motor. Both motor and controller are connected to each other with four connectors as shown in the figures. Motor and controller have mounting bosses at four places each. One end of each connector is bolted on the boss of motor and other end of connector is bolted on corresponding boss on controller. The connector is made of heat resistant material (For example 30% glass filled nylon 66 or polybutylene terephthalate (PBT).Thus the motor and controller are thermally isolated and heat from motor is not transferred to controller through connector. The shroud is also bolted to controller at various locations.
The fan is of axial flow type that sucks air from one side and throw it to the otherside.
The motor and controller are of the IP67 type to protect them from water and dust for a long time.
This compact arrangement of mounting the controller, fan, and motor eliminates the complexity of packaging, reduces the cost of the system, and increases the availability of space by avoiding long connecting wires between the motor and controller.
This compact arrangement of mounting the controller, fan, and motor reduces the length of electrical wires connected to them, reducing electrical losses due to long lengths of wires. It also avoids cutting of wires, avoiding power failure of the vehicle. This also reduce malfunction of controller and improves its life.
This compact size also eliminates the requirement for liquid cooling of the motor, thus saving space and cost.
According to another embodiment of the present invention, in the cooling system for an integrated motor and controller as mentioned above, the motor or prime mover generating the power is selected from the group of 1. Electric motor, 2. Internal Combustion Engine 3. Hybrid engine (combination of electric motor and I C Engine)
According to another embodiment of the present invention, in the cooling system for the integrated motor and controller as mentioned above, the motor is integral with a gearbox.
According to another embodiment of the present invention, the output power from the motor is transferred to drive wheel of a vehicle through a type of transmission selected from the group of 1. Fixed gear transmission, 2. Changeable gear transmission, 3. Automatic gear transmission, 4. Continuously Variable Transmission (CVT), 5 Chain transmission, 6. Belt transmission.
The applicant also developed an integrated motor and controller for an automotive vehicle, wherein it comprises:
a) An electric motor,
b) A controller,
c) A fan,
Wherein;
I. The motor, controller and fan are arranged co-axially in the axial direction of the motor shaft.
II. The fan is mounted on a motor shaft and arranged between the motor and the controller.
III. The controller is thermally isolated from the motor.
IV. The motor and controller are cooled by the said fan.
V. Preferably motor and controller are isolated by a heat resistant connector disposed of between them.

BRIEF DESCRIPTION OF DRAWINGS:

Figure 1 is a pictorial front view of an integrated motor and controller according to one embodiment of the present invention.
Figure 2 is a pictorial top view of an integrated motor and controller according to one embodiment of the present invention.
Figure 3 is a pictorial perspective view 1 of an integrated motor and controller according to one embodiment of the present invention.
Figure 4 is a pictorial perspective view 2 of an integrated motor and controller according to one embodiment of the present invention.
Figure 5 is a pictorial isometric view 2 of an integrated motor and controller according to one embodiment of the present invention.
Figure 6 is a pictorial view of an integrated motor and controller according to one prior art of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT:

Embodiments of present invention will now be explained with the help of figures herein below. All the aspects described herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope herein without departing from the spirit and scope thereof, and the present invention herein includes all such modifications.

Referring to Figure 1 to 5, According to one embodiment of the present invention, a cooling system for an integrated motor and controller (10) comprises; a motor (1), a controller (2), a fan (3), a connector (4), a shroud (5) and a deflector (6). The motor (1), the controller (2), and the fan (3) are arranged in the axial direction (11) of the motor shaft (9).The controller (2) is thermally isolated for the motor (1) by mounting on the motor (1) with a heat resistant connector (4) to avoid heat transfer from the motor (1) to the controller (2). The fan (3) is mounted on the motor shaft (9) and arranged between the motor (1) and the controller (2). The shroud (5) is disposed around the motor (1), the fan (3), and the controller (2). The shroud (5) has a varying cross section, particularly lower diameter at the portion (12) disposed around the fan (3). A deflector (6) is provided on the shroud (5) at a lower diameter position (12) towards the controller (2) side.

The fan (3) is an axial type fan which is rotated in the direction such that the atmospheric air is sucked from the controller (2) side. Because of the shape created by the shroud's reduced diameter (12) and the deflector (6) attached to the shroud (5), air (16) is deflected towards the fan's centre. This sucked air cools the controller (2) while travelling over it in the gap (7) between the shroud (5) and the controller (2) and through fins (13) of the controller (2). Furthermore, the air (17) is thrown towards the motor (1) by the rotation of the fan (3). The air (17) is guided over the motor (1) and flows in the gap (8) between the shroud (5) and the motor (1) and through the fins (14) of the motor (1), thus cooling the motor (1) more efficiently before exiting from the other end.

The air drawn in by the fan (3) is at ambient temperature. It flows over the controller (2), which is at a moderately high temperature (for example, 70 °C). The sucked air cools the controller (2) while the temperature of the air increases moderately. This air flows over the motor (1), which is at a high temperature (for example, 120 °C). This air is relatively cool as compared to the motor temperature. Therefore, it cools the motor (1) while being guided over it and exits at a high temperature from the other end of the motor (1). Thus, a single fan (2) is used to cool both the motor (1) and the controller (2) effectively.

The controller (2) is arranged in the axial direction (11) of motor (1) near the fan side of motor. Both motor (1) and controller (2) are connected to each other with four connectors (4) as shown in the figure 4. Motor (1) and controller (2) have mounting bosses (15) at four places each. One end of each connector (4) is bolted on the boss (15) of motor (1) and other end of connector (4) is bolted on corresponding boss on controller (2). The connector (4) is made of heat resistant material (For example 30% glass filled nylon 66 or polybutylene terephthalate (PBT)). Thus the motor (1) and controller (2) are thermally isolated and heat from motor (1) is not transferred to controller (2) through connectors (4). The shroud (5) is also bolted to controller (2) at various locations.

The fan (2) is of axial flow type that sucks air from one side and throw it to the other side.

The motor (1) and the controller (2) are of the IP67 type to protect them from water and dust for a long time.

A motor and controller cooling system according to one of the prior art is shown in the figure 6. A controller (22) is directly mounted on the motor (21) and a fan under the fan cover (23) is mounted on the motor shaft which cools the controller (22). As the controller (22) is directly mounted on the motor (21), the heat from motor (21) is transfer to controller (22). Cooling fan is not sufficient to cool the controller (22). This leads to malfunction of the controller (22) due to overheat.

This compact arrangement of mounting the controller, fan, and motor eliminates the complexity of packaging, reduces the cost of the system, and increases the availability of space by avoiding long connecting wires between the motor and controller.
This compact arrangement of mounting the controller, fan, and motor reduces the length of electrical wires connected to them, reducing electrical losses due to long lengths of wires. It also avoids cutting of wires, avoiding power failure of the vehicle. This also reduce malfunction of controller and improves its life.
This compact size also eliminates the requirement for liquid cooling of the motor, thus saving space and cost.

According to another embodiment of the present invention, in the integrated motor and controller, as mentioned above, the motor or prime mover generating the power is selected from the group of (1. Electric motor, 2. Internal Combustion Engine 3. Hybrid engine, a combination of electric motor and I C Engine).
According to another embodiment of the present invention, in the integrated motor and controller, as mentioned above, the motor is integral with gearbox.
According to another embodiment of the present invention, the output power from the motor is transferred to drive wheel of a vehicle through a type of transmission selected from the group of (1. Fixed gear transmission, 2. Changeable gear transmission, 3. Automatic gear transmission, 4. Continuously Variable Transmission (CVT), 5 Chain transmission, 6. Belt transmission).

With above embodiments of the invention the problem mentioned earlier in the automotive vehicle can be solved effectively.

Although the invention has been described with regard to its embodiments, specific embodiments, and various examples, which constitute the best mode presently known to the inventors, it should be understood that various changes and modifications as would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. All changes that come with meaning and range of equivalency of the claims are to be embraced within their scope.
,CLAIMS:WE CLAIM:

Claim 1: A cooling system for an integrated motor and controller, comprises:
e) A fan,
f) A shroud,
g) A diffuser,
h) A connector,
Wherein;
the motor, controller and fan are arranged co-axially in the axial direction of the motor shaft.

Claim 2: The cooling system for an integrated motor and controller as claimed in claim 1 wherein; the fan is mounted on the motor shaft and arranged between the motor and the controller.

Claim 3: The cooling system for an integrated motor and controller as claimed in claim 2 wherein; the motor and controller are isolated by a heat resistant connector disposed of between them.

Claim 4: The cooling system for an integrated motor and controller as claimed in claim 3 wherein; the motor and controller are cooled by the said fan.

Claim 5: The cooling system for an integrated motor and controller as claimed in claim 4 wherein; the shroud is disposed around the motor, fan, and controller.

Claim 6: The cooling system for an integrated motor and controller as claimed in claim 5 wherein; the shroud has a varying cross section and minimum diameter at the portion disposed around the fan.

Claim 7: The cooling system for an integrated motor and controller as claimed in claim 6 wherein; the deflector is provided on the shroud at a minimum diameter position towards the controller side.

Claim 8: The cooling system for an integrated motor and controller as claimed in claim 7 wherein; the fan is of axial flow type.

Claim 9: The cooling system for an integrated motor and controller as claimed in claim 8 wherein; the motor and controller are of the IP67 type.
Claim 10: The integrated motor and controller as claimed in claim 1 to 9, the motor or prime mover generating the power is selected from the group of Electric motor, Internal Combustion Engine, Hybrid engine.
Claim 11: The cooling system for an integrated motor and controller as claimed in claim 10 wherein; the motor is integral with a gearbox.
Claim 12: The cooling system for an integrated motor and controller as claimed in claim 11 wherein; the output power from the motor is transferred to drive wheel of a vehicle through a type of transmission selected from the group of fixed gear transmission, changeable gear transmission, an automatic gear transmission, continuously variable transmission (CVT), chain transmission, belt transmission.
Claim 13: The integrated motor and controller for comprises:
d) An electric motor,
e) A controller,
f) A fan,
Wherein;
the motor, controller and fan are arranged co-axially in the axial direction of the motor shaft.

Claim 14: The integrated motor and controller as claimed in claim 13 wherein; the fan is mounted on a motor shaft and arranged between the motor and the controller.

Claim 15: The integrated motor and controller as claimed in claim 14 wherein;
the controller is thermally isolated from the motor.

Claim 16: The integrated motor and controller as claimed in claim 15 wherein;
the motor and controller are cooled by the said fan.

Claim 17: The integrated motor and controller as claimed in claim 16 wherein; the motor and controller are isolated by a heat resistant connector disposed of between them.