FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION:
"Direct Electric Drive with Two Speed Zero Torque Interrupt Auto Shift Mechanism"
2. APPLICANT:
(a) NAME: Magna Steyr India Pvt. Ltd
(b) NATIONALITY: Indian Company registered under the
provisions of the Companies Act-1956.
(c) ADDRESS: 1st Floor, Kapil Zenith, Sr. No. 55
Hissa No.1, Bavdhan Khurd,
Tal. Mulshi, Pune -411021 M.S. INDIA,
3. PREAMBLE TO THE DESCRIPTION:
COMPLETE
The following specification particularly describes the invention and
the manner in which it is to be performed.

Direct Electric Drive with Two Speed Zero Torque Interrupt Auto Shift
Mechanism
Filed of the invention
The present invention relates to an electric drive system, more particularly, the present invention relates to an electric motor with clutch and sprockets wheels for transmitting torque to a driven loaded system, like automotive propulsion.
Background of the invention
Standard electric motors do not have any kinetic energy when at null speed. The torque and power characteristics of an electric motor are shown in figures la & lb. The torque shows a seep decrease as the rotational speed increases and a curved path gradually increasing from zero angular speed and again decreasing to zero at maximum angular speed.
Generally, to match with the required power of the application, the total size of the motor is increased, which increases the weight of the system, space requirement, electrical energy needed for powering the motor, (Load on the wiring due to excess current consumption), controller size and mounting requirements.
Prior Art
Existing electric motors are AC and DC motors. These motors have been manufactured and used in various types and applications since a very long time. But all these lack the very much required 'Initial Power'. They have a very high initial torque, but it cannot be used efficiently unless the motor crosses a certain critical speed. Figure la shows a graph of torque verses rotational speed of an electric drive of the prior art and figure 1 b shows a graph of torque verses angular speed depicting power of an electric drive of the prior art.

Object of the present invention
Object of the present invention is to provide an electric drive with dual speed reduction means, which is easy to construct, light in weight, compact in size, and capable of saving energy.
Another object of the present invention is to provide an electric drive with dual speed reduction means, which eliminate the need of a 'gearbox' or a variable speed transmission.
Yet another object of the present invention is to provide an electric drive with dual speed reduction means, which has increased thermal, electrical, and mechanical efficiency.
Further object of the present invention is to provide an electric drive with dual speed reduction means, which produces high power right from zero speed of the electric drive, till mid-speed.
One more object of the present invention is to provide an electric drive with dual speed reduction means; which is to provide the ultimate electric drive technology to drive all electric and hybrid-electric vehicles.
Another object of the present invention is to use the 'zero-torque interrupt shift mechanism' to create a 3, 4, 5, 6, 7, 8 speed gearbox for automotive propulsion / machinery use.

Brief description of figures
Figure 1a shows a graph of torque verses rotational speed of an electric drive of the prior art;
Figure lb shows a graph of torque verses angular speed depicting power of an electric drive of the prior art;
Figure 2 shows the cross sectional view of an electric drive in accordance with the present invention;
Figure 3 shows another cross sectional view of an electric drive of figure 3;
Figure 4 shows side cross sectional view of the electric drive of figures 3 and 4; and
Figure 5 shows a graph of torque verses angular speed depicting power of an electric drive in accordance with the present invention.
Detail description of the invention
The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
Referring now figure 2 & 3, sectional side views of an electric drive (100) capable of producing higher power right from zero RPM in accordance with the present invention is illustrated. The electric drive (100) includes a shaft (10), a housing (12), a cover (14), an electric motor (20), a drive drum (30), a driven drum (32), a plurality of liner pins (34) (for the purpose of explanation the present invention

includes three liner pins), a driven shaft (36), a first pair of sprocket and a claim (38) and a second pair of sprocket and a claim (40). The cover (14) is disposed over the shaft (10) with a bearings therebetween (14a). The housing (12) is preferably cylindrical in shape with a side closed an opening thereof for passing the shaft (10). Other side opposite to the closed side is covered by the cover (14) and secured to the housing (12) with bolts (14b) therebetween.
Further, the drive drum (30) is secured inside the housing (12) with bearings (30a) therebetween. Preferably, the bearings (30a) are needle roller bearing. The bearings can be replaced by any other type of bearing which may be obvious to a person skilled in the art. The drive drum (30) is also secured over the shaft (10) with a bearings (30b) therebetween. There are additional bearings (30c) disposed between the drive drum (30) and the housing (12).
Referring again to figures 2 & 3, the electric motor (20) is secured to the cover (14) with the help of pins (26). Specifically, the electric motor (20) is an integral brushless direct current motor. The electric motor (20) includes magnets (22), electric windings (24) and a plurality of pins (26). The electric windings (24) are disposed over the plurality of pins (26). The magnets (22) are configured in a cylindrical shape and are disposed around the electric windings (24). The electric windings (24) are stationary and magnets (22) rotates upon supplying electric current to the electric winding (24). Specifically, the magnets (22) are secured to the drive drum (30). The drive drum (30) rotates along with the magnets (22).
Further, the driven drum (32) is disposed juxtaposition of the electric winding (24) and rigidly secured over the shaft (10) inside the housing (12). The driven drum (32) is a circular 'C shaped channel. The driven drum (32) includes a first frictional surface (32a). The first frictional surface (32a) is an precision machined surface. The three liner pins (34) are secured to the inner portion of the drive drum (30). The three liner pins (34) are also secured by springs (34a) and extend radically upon acted by centrifugal force. As the three liner pins (34) are secured

to the drive drum (30), rotation of drive drum (30) rotates the three liner pins (34) as shown in figure 3. In an embodiment, the spring (34a) is a compression spring as shown in figure 4. Each of the liner pin (34) includes a second frictional surface (34b) which is an abrasive surface, facing towards the first frictional surface (32a) of the driven drum (32). The second frictional surface (34b) gets secured to the first frictional surface (32a), when the centrifugal forces exerted upon the three liner pins (34) over comes the force of the spring (34a), thus engaging a contact between the drive drum and driven drum, and thereby rotating the shaft (10) therewith.
Further, the driven shaft (36) is secured over the housing (12) with bearing (36a) therebetween. The first pair of sprocket and a chain (38) comprising two sprockets and a chain. One of the sprockets is secured to a one way clutch bearing (38a) that is further secured over the drive drum (30) and a second sprocket is secured over the driveri shaft (36) and connected to the first sprocket with a chain thereover. Further, the second pair of sprocket and a chain (40) comprising two sprockets and a chain. One of the sprockets is secured over the shaft (10) and a second sprocket is secured over the driven shaft (36) with a chain thereover.
Initially, when the electric motor (20) starts rotating and the liner pins (34) are not coupled with the driven drum (32). The first pair of sprocket and a chain (38) driven by the drive drum (32) drives the driven shaft (36). As the speed of the electric motor (20) increases, the liner pins (34) overcome the resistance force of the spring (34a) by the centrifugal force generated due to rotation, and expand to couple with the driven drum (32), to rotate the shaft (10) and the second pair of sprockets and a chain (40) thereby rotating the driven shaft (36) directly and also over running the first pair of sprocket and the chain (38) through one way bearing, thereby providing a two speed shift mechanism without any torque interruption.

Figure 5 shows a graph of torque verses angular speed of the electric drive (100). The figure 5 shows a 40% gain on overall power, without increasing in motor size and 65% increase at zero speed condition of the output shaft.
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment.
Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter.
The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention.

I Claim:
1. An electric drive capable of producing higher power and torque right from low RPM to high RPM of the final output shaft (driven shaft), the electric drive comprising:
a shaft;
a housing and a cover secured over the shaft with bearing therebetween;
a drive drum secured inside the housing and over the shaft with bearings between the drive drum and the housing, and between the drive drum and the shaft;
magnets, electrical windings and a plurality of pins disposed inside the drive drum and secured over to the cover to configure an electric motor for rotating the drive drum, characterized in that:
a driven drum disposed juxtaposition of the electric winding and rigidly secured over the shaft inside the housing, wherein the driven drum has a first frictional surface;
a plurality of liner pins disposed inside the driven drum and secured to the drive drum, wherein each of the liner pin of the plurality of liner pins having a second frictional surface facing the first frictional surface of the driven drum and springs thereof;
a driven shaft secured over the housing with bearings therebetween;
a first pair of sprockets and a chain secured to the driven shaft and the drive drum with an one way clutch bearing therebetween, wherein the one way clutch bearing is secured to the drive drum;
a second pair of sprockets and a chain secured to the driven shaft and the shaft,
wherein upon rotating the electric motor, the drive drum starts rotating thereby rotating the first pair of sprockets and a chain, with increasing in speed of the motor, the plurality of liner pins overcomes resistance of the spring, and expand centrifugally to secure and rotate the driven drum thereby rotating the second pair of chains and sprockets and establishing direct coupling with the driven shaft and

over running the first pair of sprockets and the chain though the one way bearing, thereby providing a two speed shift mechanism without any torque interruption.
2. The electric drive as claimed in claim 1, wherein the bearings between the drive drum and the housing are needle roller bearings.
3. The electric drive as claimed in claim 1, wherein the spring is a compression spring.
4. The electric drive as claimed in claim 1, wherein the electric motor is an integral brushless Direct Current motor.
5. The electric drive as claimed in claim 1, wherein the cover is secured to the housing by bolts.
6. The electric drive as claimed in 1, wherein the two speed shift mechanism is a potential benchmark for producing similar higher speed auto shift, zero torque interrupt transmissions.