FORM 2
THE PATENT ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION - Design and Assembly of Electric Hybrid Conversion
System for Scooter
2. APPLICANT
(a) Name: NEXTGEN TECH INITIATIVES PVT LTD
(b) Nationality: Indian
(c) Address: Plot A-27, Rd No. 10, Wagle Industrial Estate, MIDC, Behind Old Passport Office, Thane (W) 400 604, Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

INTRODUCTION TO THE INVENTION
Rising costs of fossils based fuel, resulting in increased operational costs of vehicles, emission norms getting stricter by the day to curb vehicular pollution and its impact on the environment and the need to reduce dependency on imports for fuel is driving the initiative to look at low cost alternative means of transportation. Designing a system that can help achieve the above and which is affordable and within the means of the masses is need of the hour. One such system is the present invention which is in the form of a conversion system can help transform an existing, petrol dependent IC engine driven scooter into a less polluting, eco-friendly and low operational cost plug-in hybrid electric scooter.
The present invention relates to a hybrid electric scooter. More particularly, the present invention relates to a drive train, including an electric motor and battery used for converting an existing IC engine scooter in to a plug-in hybrid electric scooter, and to a hybrid electric scooter incorporating the electric drive train.
Accordingly, it is an object of the present invention to provide a much simpler hybrid electric drive to the scooter by providing the electric part of the powertrain in the front wheel of the scooter. This would enable a faster and simpler conversion kit to convert existing IC engine driven scooters to hybrid electric scooters.
It is another object of the present invention to simplify the installation of an electric motor and battery without much modification to the existing design of the scooter and thereby keep the design costs low.
SUMMARY OF THE INVENTION
In order to achieve the above objects, the present invention according to a first aspect thereof provides the electric drive by a brushless DC motor of the Hub type. This motor is mounted in the front wheel of the vehicle. This motor is of 850 W capacity and is operated by a 48V battery system. These specifications of the motor are for the test vehicle and can be customized as per user's preferences.
The present invention according to a second aspect thereof, in addition to the first aspect, is characterized in that the drive train includes the motor controller of MOSFET & PWM type. The controller is mounted in the front fork of the scooter below the head light and display panel. The controller manages the operation of the motor in the electric mode and the regeneration operation during IC engine mode.
The present invention according to a third aspect thereof, in addition to one of the first through second aspects, is characterized by a battery system of 48 V 24 Ah capacities that supplies electric power. There are four individual batteries each of 12V 24 Ah capacities. All four batteries are connected in series to make a 48V system. All four batteries are mounted in the storage section of the scooter. The battery type and technical specifications of battery can be customized as per user's preferences.

The present invention according to a fourth aspect thereof, in addition to one of the first through third aspects, is characterized by the accelerator which is a unique design that enables both the electric motor and the engine to be accelerated using the same handle mounted grip-type accelerator. This design incorporates the cable type arrangement required for revving the IC engine and the potentiometer arrangement to increase the speed of the motor in a single unit.
The present invention according to a fifth aspect thereof, in addition to one of the first through fourth aspects, is characterized by designing a front fork and suspension of the scooter that is strengthened compared to standard scooters to take the weight of the BLDC motor and also provides the mounting for the motor on the front side.
The present invention according to a sixth aspect thereof, in addition to one of the first through fifth aspects, is characterized by designing a conversion kit that converts an existing scooter into an plug-in hybrid electric scooter and such a kit that comprises of the electric drive train, the battery system, the necessary modifications required for the installation of the entire electric drive train all provided as a simple bolt-on system that can be installed irrespective of the make and model of the existing scooter.
EFFECTS OF THE INVENTION
The invention helps to create low emissions, fuel-saving plug-in hybrid electric scooter from an existing internal combustion engine scooter. For the city route selected for testing, the test vehicle in stock condition gives a mileage of 50km per litre of petrol. With the addition of the electric drive that can operate independently, the mileage improves to approximately 95km per litre per charge; where-in 45km are obtained by driving the scooter on electric mode. Thus an improvement of about 90% in range per litre per charge* (* the performance specifications of such PHEV will improve with further advancements in technology of electric powertrain components such as battery, motor, controller, BMS, etc) can be achieved in city driving conditions which in turn mean that significant reduction in CO2 emissions can also be achieved per litre of petrol consumed in city driving conditions. Since the invention helps to convert the existing scooter into a low emissions, fuel saving vehicle -i. It increases the life expectancy of the existing vehicle,
ii. Provides a cost-effective solution to reduce the emissions from vehicles that are already on the road
iii. Helps in conserving the usage of petrol thereby helping in reducing the import bills of fossil fuel based fuels for the nation

The hybrid electric scooter can be operated in three modes
i. Electric mode - The BLDC motor in front wheel provides a direct drive to the front wheel

ii. Engine mode - IC engine provides the drive to the rear wheel through the continuously variable transmission (CVT)


iii. Regenerative mode - The front wheel mounted BLDC hub motor acts as a generator and charges the battery as required while in the regenerative mode

iv. Combined mode-The BLDC motor in front wheel provides a direct drive to the front wheel and the IC engine provides the drive to the rear wheel through the continuously variable transmission (CVT)


This plug-in hybrid electric scooter can be compared with the existing petrol engine scooter and a fully electric two-wheeler as shown in the table below. The comparison has been made for features like maximum speed, range, mileage, modes of operation, pollution control, etc that can be considered important for end-users. The specifications of such plug-in hybrid electric scooter will improve with further advancements in technology of electric powertrain components such as battery, motor, controller, BMS, etc.

Sr.Num. Features Two Wheeler (IC Engine) Two Wheeler (All Electric) Two Whitltf {Hug-In Hybrid Electric Scooter)
Conceptualated, Deilgneded & Functional
Prototype Built by NtxtGen Tech Initiatives Pvt.
Ltd.
1 Max. Speed High (>60 kmph) Moderate (Typical speed range of
existing vehicles is between under 25
kmph to about 45 kmph) High (>60 kmph)
2 Range (Total km travelled on full tank of fuel/Charge/ per
liter per charge) High
(> 200 km for a FULL fuel tank
assuming Fuel tank capacity Is more
than 4 litres and city Mileage Is about
than SO km per litre) Low
(About 40 to 60 km per FULL Charge
considering typical city drive
conditions) Highest
(Range of existing IC Engine two wheeler gets
extended with additional mileage driven in all
electric mode. The batteries powering all electric
mode are charged by either EXTERNAL power plug
OR in a REGENERATIVE mode while Scooter is run
on IC Engine)
3 Mileage (Per Uter/Per
Charge/ Per Later Per
Charge) High (>50 km per litre for a typcial mass produced IC Engine Motor Cycle) Low
(<60 km per FULL Charge for existing
all electric two wheelers) Highest
(As it sums the total mileage of IC Engine mode and
all electric mode and can be represented as Per
liter Per Charge)
4 Modes of Operations Single (ICE) Single (Electric Motor) Four Modes: 1. ICE 2. All Electric 3. ICE with Regenration Mode (On or Off type) 4. Combined
electric & IC engine (Each Mode would give different overall Range)
5 Noise Pollution & Vibrations Present Absent Absent in All Electric Mode. Present in other Modes.
6 Refuel / Recharge Time Per Km Low
(However, the watting period for fuel
stations In urban area can add to
refilling time) High
{In case of Lead Acid battery)
However, with better infrastructure
and technology, such as fast charging
stations and advanced batteries such
as Lithium-lon.etc the charging time
would be lower in future. (i) Low: (In case of Refueling petrol tank, assuming
no queues at fuel stations) (ii) Moderate: (In case
of extensive usage of Renerative Mode due to
Range Extension) (III) High: In case of Charging
batteries with external power source (without any
advanced technology In battery or charging
Infrastructure) (iv)Very Low: (In case of Battery
Swapping Arrangement). Thus, substantial scope to
create more friendly charging Infrastructure.
7 Scope to improve
performance
specifications such as
range, speed, etc. with
advancements In
Technology Relatively Low High
(Battery as well as charging
technology are being improved
substantially with Increasing R&O
spend and sricter environmental
compliances.) High
(Battery as well as charging technology are being
improved substantially with increasing R&O spend
and sricter environmental compliances.)

TECHNICAL SPECIFICATIONS OF THE INVENTION
The technical and performance specifications are based on the test vehicle built for the purpose of demonstration of the concept and design. The specifications of such PHEV will improve with further advancements in technology of electric powertrain components such as battery, motor, controller, BMS, etc.
Technical Specifications (of Test vehicle):

Motor Type BLDC Hub Motor
Motor Power 850 W; 48V system
Motor Controller MOSFET based PWM type Kelly Controller
Battery Capacity 48 V 24 Ah
Battery charging Plug-in charge point
Battery Charger 48 V / 3A; Input AC: 180-240V 50/60 Hz
Regeneration mode Yes
Brakes Front - Drum; Rear - Drum
Engine type 4 stroke air-cooled
Engine displacement 109 cc
Engine power Max8bhp@7500rpm
Transmission Automatic
Accelerator Combined electro-mechanical type
Performance Specifications (of Test vehicle):

Travel Range 45 km per charge (Electric mode)

50 kmpl (city); 60 kmpl (highway) (IC engine mode)
Speed 35 kmph max (Electric mode)

85 kmph max (IC engine mode)

DESCRIPTION OF INVENTION
BRIEF DESCRIPTION OF THE DRAWINGS
i. Fig 1: General Arrangement
ii. Fig 2: Combined Accelerator
iii. Fig 3: Front Wheel Assembly RHS
\iv. Fig 4: Front Wheel Assembly LHS
v. Fig 5: Front Wheel Fork Design
vi. Fig 6: Front suspension arrangement
vii. Fig 7: Complete Motor drive
viii. Fig 8: Block diagram of Controller
ix. Fig 9: Controller
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
Figure 1 describes the general arrangement of the electric hybrid drive train of the scooter. This hybrid electric drive design is based on the fact, that the existing internal combustion engine drive train (Fig 1 (13)) up to rear wheel is kept unaltered .while the front wheel Drive train (Fig 1 (1)) is driven by a BLDC electric hub motor which provides a direct drive to the front wheel, thus resulting in a parallel hybrid. The major parts of this electric hybrid comprise of combined accelerator control (Fig 1- (5)) which is custom build, the Controller unit (Fig l-(3), Fig 9-(3)), the Electric Motor (Fig 1-(1)) mounted on the suspension provided through the custom build front fork (Fig 1- (2)). The electric power is derived from the battery bank (Fig 1- (12)) housed into the storage space of the scooter, thus maintaining the new additions within the bodyline of the vehicle and preserving the bilateral symmetry of loads for maintaining the balance of the vehicle. Battery charging point is located (Fig 1 (10)) at a very convenient and easy accessible point on the vehicle and charging is done by an external 3A charger. The custom build cable harness (Fig l-(4)) provided under the rider's seat is for the power & control circuits and regeneration circuit of the controller (Fig l-(3)), the combined accelerator (Fig l-(5)), brake safety switch interlock (Fig l-(6)), the regeneration mode on and off switch (Fig 1 (43)), charging circuit and vehicle operations. Custom designed Mud Guard (Fig l-(ll)) avoids mechanical damage and interferences.
Figures 3, 4, 5 & 6 show the direct electric drive mounted in the front wheel and the front suspension and custom build fork assembly. The BLDC hub motor (Fig 1-(1), Fig 3-(l), Fig 4-(l) & Fig 6-(l)) is mounted on the custom designed fork (Fig l-(2), Fig 3-(2), Fig 5-(2) & Fig 6-(2)) with the help of shock absorber spring units (Fig 3-(42) & Fig 6-(42)) and the swing arm levers (Fig 3-(33), Fig 3-(34)). The arrestor plates (Fig 3-(38) & Fig 3-(19)) and its fasteners (Fig 3-(37)) & Fig 4-(20)) are provided to arrest the accidental rotation of the motor axle (Fig 3-(39)), which needs to be fixed, thereby allowing only rim and the tyre (Fig 3-(41)) to rotate with full traction power and maintaining the dynamics and steering control. The Motor axle is securely held in position using the nuts and locknuts strongly for safety. The grip on the tire (Fig 3-(41)) conforming to the self-righting property gives proper road grip and traction to the driver. Vehicle dynamics is preserved due to custom designed suspension and

brake control (Fig 3-(36) & Fig 3-(40)) in line with the traction provided by the Motor. The pivot (Fig 3-(38)) action for the suspension and the shock absorbers (Fig 3-(42)) is provided by the pivot pins (Fig 3-(38) & Fig 4-(21)) with the help of fasteners (Fig 3-(37) Fig 4-(22)). The suspension system at other end is holding the motor axle with the help of brackets (Fig 3-(35); Fig 4-(23) & Fig 4 - (24)) and pair of nut-lock nut assemblies (Fig 4-(23) (24) & Fig 3-(33) (34)). The drive from the wheel is transmitted to the vehicle in the following manner- from BLDC motor (Fig 3-(l), 4-(l) & Fig 6-(l)) to arrestor plates (Fig 3-(38) & Fig 3-(19)) then to the suspension linkage (Fig l-(8) & Fig 6-(8) to the custom designed fork (Fig l-(2), Fig 3-(2), Fig 5-(2) & Fig 6-(2)) and from the custom designed fork to the chassis of the vehicle and hence the vehicle. Motor assembly (Fig 7-(l)) is shown with the front axle and wheel drive, balanced and symmetrically to the fork axis thereby preserving the steering dynamics and safety.
Front brakes and speedometer sensors (Fig l-(9)) are provided on the motor (Fig 1-(1), Fig 3-(l), Fig 4-(l) & Fig 6-(l)). Digital speed sensing by a sensor ring (Fig 4-(9)) and a speed sensor (Fig 4-(17)) mounted on brackets (Fig 4 - (23)(24)) is used to measure the speed as the custom solution to the mechanical speedometer, which is removed to accommodate the motor drive assembly during the conversion of the vehicle to electric hybrid.
Figure 2 explains the uniquely designed electro-mechanical accelerator (Fig l-(5)) that performs the function of accelerator for both electric and engine drives and hence gives ease of operation to the driver maintaining their driving habits. The grip (Fig 2- (29)) operates both electric and internal combustion engine accelerator in unison. The cable operated mechanical system (Fig 2-(26)) provides the accelerator function for the internal combustion engine. The magnetic coupling and sensor (Fig 2-(25)) pass on signal to controller (Fig l-(3), Fig 9-(3)) and provide the accelerator function for the electric drive. Thus hybrid operation through the common accelerator is easily achieved. The custom designed body parts (Fig 2-(27)) impart strong support to the accelerator assembly. Safety lock (Fig 2-(28)) prevents accidental rotation of body. The safety interlock switch (Fig 2-(30)) prevents accidental running of motor while brakes are engaged. The brake lever (Fig 2-(31)) is used to actuate the switch (Fig 2- (30)).
Two Independent Electric key switches (Fig 1-(14) & Fig 1-(15)) are provided to isolate electric and engine mode. The operation in combined mode is possible due to the continuously variable transmission and the combined accelerator control without much affecting the vehicle dynamics. The custom-built cable harness with smart circuits enable the vehicle to run in electric only or IC engine only or combined mode depending upon the required tractive effort which takes into consideration factors such as the road conditions where the vehicle is being driven, payload of the vehicle, etc.
Figure 9 shows the motor controller and figure 8 refers the block diagram of Controller.

Motor reversal is permanently defeated in controller (Fig 9 (3)) to prevent motor reversal. This is due to the fact that the front wheel drive motor for two wheeler scooter should never go through reverse rotation of motor for the rider's safety. A Ik ohm pre charging resistor is added across the Mains contactor. Similarly, IK ohm resistor is also added across the key switch (Fig 1-(14) & (15)) for electric mode. Magnetically coupled accelerator Fig (l-(5)) through control wiring (Fig l-(4)j interacts with the controller Fig 9- (3) to give desired speed control. The controller provides the proportionate power as per the torque speed demand as directed by the accelerator. Thermister control is provided internally through this controller for the protection of the motor winding from over-heating during rotor lock situation. Thus protection interlocks are achieved. Further, the controller (Fig 9-(3)) provides a regeneration mode to conserve the free-wheeling rotational energy of the front wheel and also to regenerate during braking done by either front or rear wheel brakes, thereby charging the batteries. Thus this action is capable to further add extra miles as a result of regeneration.
Although this present invention has been described herein with respect to a number of specific illustrative embodiments, the foregoing description is intended to illustrate, rather than to limit the invention. Those skilled in the art will realize that many modifications of the illustrative embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.

CLAIMS
We claim,
1. The concept of the electric drive train that can be used,to convert an existing petrol engine driven scooter to plug-in hybrid electric scooter by mounting the electric drive train in the front wheel and that can run in either electric or IC engine mode independently and simultaneously; '
2. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 1, wherein the BLDC hub motor is mounted in the front wheel of the scooter and it is providing a direct drive in the front wheel;
3. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein there is a uniquely designed electro-mechanical accelerator that in a single assembly provides function of accelerator for both internal combustion engine and electric drive;
4. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein the controller is placed in the front section of the scooter frame;
5. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein the front suspension design of the existing scooter is redesigned and consists of an arrangement of support brackets and linkages, arrestor plates to prevent accidental rotation of motor axle and pair of stiffener brackets that help to transmit the drive to propel the vehicle^
6. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein the battery pack is mounted in storage compartment under the seat, thereby maintaining the centre of gravity in the same longitudinal plane as that of the existing scooter;
7. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein the freewheeling front wheel of the standard IC engine driven scooter is now a drive element providing drive during the electric mode and acting as a generator to charge the batteries while in regeneration mode;
8. The design of an electric drive train for a plug-in hybrid electric scooter according to claim 2, wherein there is a custom-built cable harness with smart circuits that enable the vehicle to select between various modes of operation like electric only, IC engine only or combined mode depending upon the required tractive effort which takes into consideration factors such as the road conditions where the vehicle is being driven, payload of the vehicle, etc;
9. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 2, wherein the BLDC hub motor is mounted in the front wheel of the scooter and it is providing a direct drive in the front wheel;

10. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein there is a uniquely designed electro-mechanical accelerator that in a single assembly provides function of accelerator for both internal combustion engine and electric drive;
11. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein the controller is placed in the front section of the scooter frame;
12. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein the front suspension design of the existing scooter is redesigned and consists of an arrangement of support brackets and linkages, arrestor plates to

prevent accidental rotation of motor axle and pair of stiffener brackets that help to transmit the drive to propel the vehicle;
13. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein the battery pack is mounted in storage compartment under the seat, thereby maintaining the centre of gravity in the same longitudinal plane as that of the existing scooter;
14. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein the freewheeling front wheel of the standard IC engine driven scooter is now a drive element providing drive during the electric mode and acting as a generator to charge the batteries while in regeneration mode;
15. A plug-in hybrid electric scooter comprising of an electric drive train according to claim 9, wherein there is a custom-built cable harness with smart circuits that enable the vehicle to select between various modes of operation like electric only, IC engine only or combined mode depending upon the required tractive effort which takes into consideration factors such as the road conditions where the vehicle is being driven, payload of the vehicle, etc.