DESC:TECHNICAL FIELD
[0001] The present subject matter relates generally to motor vehicles, and more particularly to a housing assembly accommodating a master control device mounted to the motor vehicles.
BACKGROUND
[0002] Generally, a motor vehicle includes an internal combustion engine and/or an electric motor, which is also referred to as traction motor, that are used for providing motion to the vehicle. Generally, the internal combustion engine is operated or controlled by a purely mechanical system or an electronic system or a combination of both. For example, the IC can be operated by a carburetor that is mechanical in nature or using a fuel injector system that typically requires electronic control. However, the traction motor, which is electrical component, requires control using an electronic master control device. Therefore, either in a hybrid vehicle incorporating an IC engine and a traction motor or in an electric vehicle incorporating only a traction motor, the master control device plays a crucial role.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description of the present subject matter is described with reference to the accompanying figures. Same numbers are used throughout the drawings to reference like features and components.
[0004] Fig. 1 illustrates a left side view of an exemplary motor vehicle, in accordance with an embodiment of the present subject matter.
[0005] Fig. 2 illustrates a perspective view of the housing assembly, in accordance with an embodiment of the subject matter.
[0006] Fig 3 illustrates an exploded view of the housing assembly, in accordance with an embodiment as depicted in Fig. 2.
[0007] Fig. 4 depicts an isometric view of the circuit board assembly with selected parts, in accordance with an embodiment of Fig. 3
[0008] Fig. 5 illustrates a cut-sectional view of the housing assembly, in accordance with the embodiment of Fig. 2.
[0009] Fig. 6 depicts an isometric view of a board and a power stud, in accordance with the embodiment of Fig. 4.
[00010] Fig. 7 depicts a sectional view of the housing assembly taken along axis X-X’, in accordance with the embodiment of Fig. 2.
[00011] Fig. 8 depicts an exploded isometric view of the cover, in accordance with the embodiment of Fig. 3.
[00012] Fig. 9 illustrated another isometric view of the cover, in accordance with the embodiment of Fig. 8.
[00013] Fig. 10 depicts an exploded view of the cover along with signal port, in accordance with the embodiment of Fig. 3.
DETAILED DESCRIPTION
[00014] Generally, every motor vehicle incorporating an electric motor that acts as one of the prime movers of the vehicle has to be controlled and operated by a master control unit. For example, in case of a hybrid vehicle, the electric motor and an internal combustion (IC) engine act as prime movers operated depending on requirement by the user. The electric motor and IC engine can be operated independently, at the same time, or one subsequent to another depending on power or mileage requirements by the user. The aforementioned functions are controlled by a master control unit.
[00015] Typically, electric vehicles or hybrid vehicles incorporated with such aforementioned electric motor that act as a prime mover is provided with a high capacity battery or high capacity battery packs for driving the electric motor. The master control unit is capable of converting the voltage from the high capacity battery, which is direct current (DC) voltage, into alternating current (AC) voltage for driving the electric motor that is for example a three phase AC electric motor. The master control unit provides the required speed and torque by varying the current that is being sent to the electric motor. The master control unit that acts as an inverter includes plurality of MOSFETs that are used for switching the three phase AC electric motor and for controlling the current flow. Moreover, the master control unit enables charging of battery from the electric motor that is functioning in generation mode during which high currents close to 5-10Amps is generated. Thus, the master control unit operating with the high currents for operating the electric motor and for charging the battery is subject to heating.
[00016] Also, the master control unit receives various signals from the user and also status signals from the various systems of the vehicle to evaluate the operation of the system of the vehicle. For example, the master control unit receives various input signals from user like throttle input, brake input, or ignition input, and various signals from the systems of the vehicle like the position sensor data from electric motor, position sensor of crankshaft, battery state of charge (SoC), or other diagnostic data. Thus, the master control unit takes critical input signals from the user and the vehicle for reliable operation of the vehicle. Moreover, the master control unit includes a DC to DC converter unit for operating the vehicle loads that operate at lower voltage compared to the electric motor operating as prime mover. Further, the master control unit also controls the ignition control in vehicles incorporating the IC engine. Also, the master control unit performs additional operations like the signal conditioning, communicating with the digital console, communicating with safety system like ABS, and communicating with the communication systems like GPS. Therefore, the master control circuit acts as brain for the motor vehicle for controlling over all operation of the vehicle.
[00017] Therefore, such a master control unit is a very essential system of the vehicle that is to be securely and reliably accommodated in the motor vehicle. Especially, in securely and reliable accommodating such master control unit in a two-wheeled or a three-wheeled vehicle is challenge as the vehicle is compact and is having an exposed layout when compared to a four-wheeled vehicle. Therefore, the master control unit should be securely packaged to avoid entry of water or moisture. Moreover, the master control circuit operates at high currents that are carried by thick current carrying cables that are to be securely connected to avoid any short circuits or un-safe incidents like fire. Moreover, such master control unit employed in a vehicle is subject to vibrations during operation of the vehicle that could affect mounting of the master control unit and could result in loosening or part failure. Additional challenge being, the weight of the master control unit/casing is to be reduced so as to reduce the own weight of the unit to improve secure mounting thereof.
[00018] Especially, the conventional master control unit is placed in a casing that generally includes a split type main enclosure, wherein the split parts are made of casting. Moreover, in addition to the split type main enclosure many covers are used because of which lot of weak portions are present in conventional designs for water/moist entry and dust entry. Such a split type design which is susceptible to water or dust entry could damage the master control circuit which is the essential unit for functioning of the vehicle. The challenge lies in providing a circuit assembly that can used in compact vehicles like two-wheeled or three-wheeled vehicles. Generally, the vehicles like two-wheeled vehicles are prone to water entry into various components of vehicles especially during servicing or heavy rains/floods or the like, which increases the probability of entry of water or dust in such conventional circuit assembly, say split type assembly. Entry of moisture is a common problem that also affects the functioning of the electrical/electronic components, which further affects the functioning of the components of vehicle like the traction motor, power source etc. leaving the user stranded with the vehicle.
[00019] Moreover, in the conventional casing assembly, the entire circuit assembly is mounted to the casing itself. However, in case of the two-wheeled or three-wheeled type compact vehicles, the casing is made compact to be accommodated therein. Such compact casings are also designed to undergo mounting support for circuit assembly by providing bosses, to support cooling elements additional holes are provided, mounting on the vehicle is done through casing, and weight of the cables is also acting on the board assembly and the casing. This increases the stress on the casing making it vulnerable for failure. Thus, one challenge is also to reduce load on the casing especially for casings used in compact vehicles.
[00020] Also, there is a need for providing electrical connection for the master control unit with other components of the vehicle which is another area prone to failure due to entry of water through the connection points. Especially, the master control unit communicates with various important vehicle statuses related signals and high currents that are to be securely communicated to the master control unit. Any failure of the connection would affect the functioning of the vehicle due to loss of vehicle status that may also compromise safety. Also, the high current cables if not securely mounted may result in short circuit thereby damaging the various components of the vehicle. Also, mounting of such thick cables adds weight on the casing whereby the casing has to be made right to withstand the vibrations and the weight of cables and the master control unit. Also the master control unit operated at high temperature and the casing should be able to withstand such high temperatures. Moreover, connection of the high current cables to the master control unit is a challenging task as the cables are heavy and are to be secured rigidly. Moreover, the housing assembly should eliminate need for additional components like fasteners for securing the components in the housing assembly as this would complicate the assembly process and increase the weight of the system.
[00021] Hence, the present subject matter is aimed at addressing the aforementioned and other problems in the prior art. It is an object of the present subject matter to provide a housing assembly for a master control device that is capable of securely accommodating the master control unit therein.
[00022] The housing assembly includes a circuit board assembly forming the master control device or the like. The housing assembly includes a chassis including at least one opening for slidably receiving and supporting the circuit board assembly therethrough.
[00023] It is an aspect of the present subject matter that the housing assembly includes a chassis and at least one cover that is capable of covering an opening of the chassis. Preferably, the covers are made of polymer with high thermal resistance and low thermal conductivity that can withstand high temperatures without deforming. Also, the covers are disposed in contact with the boards with low thermal conductivity and away from the cooling boards with high thermal conductivity. Further, the housing assembly includes gaskets disposed between chassis and the covers.
[00024] It is an aspect that the one or more cover(s) are detachably secured to the chassis for securely sealing the at least one opening and at the same time offering ease of access to the circuit board assembly that is slidably disposed.
[00025] It is a feature of the present subject matter that the chassis is provided with at least one opening and the cover that is secured thereat by fastening or the like. The cover is adapted to accommodate a first cable connecting portion and a second cable connecting portion corresponding to a first-type of cable(s) and a second-type of cable(s) respectively. The first-type of cable(s) second-type of cable(s) being different from each other. For example, the cable(s) can be a power cable, a signal cable, or the like that have different functionality.
[00026] In a preferred implementation, the chassis is made of a metallic material including any rigid yet thermally conducting material. The chassis is made of a metal with Aluminum as major element and the covers are made of a polymer. In one embodiment, two openings are provided and the openings are provided on opposite sides of the chassis.
[00027] It is a feature of the present subject matter that the chassis defines a hollow region and the chassis is provided with slots extending in the direction of reception of the master control unit, wherein the circuit board assembly is slid thereat. The chassis eliminates the need for additional mounting for the board assembly. It is an additional feature that the chassis is made by extrusion whereby any additional post tooling or fastening is eliminated. The one or more covers work in conjunction with the chassis, wherein the cover additionally support the circuit board assembly. For example, in one embodiment, the covers are provided with a stopper. The stopper at least partially supports each of boards whereby the covers also act as load bearing members instead of just sealing. Further, as the circuit assembly is slidably mounted to the chassis, the stopper of the covers acts as restricting member that restricts the slidable motion of the circuit assembly after assembly. This helps in maintaining the circuit assembly at a pre-determined positioned as the elements of the circuit assembly are interacting with other elements like the cooling bar or electrical connections, which require precise positioning for effective functioning.
[00028] It is another feature of the present subject matter that at least one board of the board assembly accommodates semiconductor components including switching components that are soldered thereto. The circuit board assembly includes one or more ports that are disposed towards the opening of the chassis, wherein the covers include a port aperture to access the port that includes a signal port or a power port for connecting cable(s).
[00029] It is a feature that at least one gasket is sandwiched between the cover and the chassis at the opening. The gasket is made of an elastic material that capable of deforming and filling any gaps. In one embodiment, the gasket includes at least an L-shaped profile abutting two sides of the cover thereby providing secure sealing to the chassis restricting entry of water or dirt that otherwise would damage the electronic components mounted to the circuit board assembly.
[00030] It is another feature that the power stud includes a threaded portion that enables securing power cables that carry high current to the circuit board assembly from a traction motor or a magneto. Thus, the power stud provides secure mounting of the cable.
[00031] It is a feature that the cover is provided with protruded guides that extend from the inward face thereof. The gasket is provided with cut-portion that is provided to match & geometrically conform to the guide whereby the gasket is located at the desired position even during assembly/removal eliminating any misalignment. Thus, it is an advantage that the cover along with the gasket provides a tight seal.
[00032] It is another feature that the cover includes a peripheral wall disposed on the inward side thereof and the peripheral wall is having substantial thickness. The peripheral wall runs about the periphery of the cover and is capable of abutting the gasket that further abuts the chassis of the housing assembly.
[00033] It is another feature that the inward face of the cover is provided with a stopper for stopping linear movement of the boards slidably mounted to the chassis. The cover with the U-shaped stopper that abuts each board eliminates the movement of the board thereby retaining the board assembly at desired location to provided proper thermal and electrical contacts.
[00034] The cover includes port apertures, which in one implementation includes an extended portion matching the profile of the port. In one implementation, the port is provided with ridges that forms gaps therebetween. One or more O-rings are provided between the ridges, wherein the O-rings are made of elastic material with higher thickness.
[00035] It is a feature that the cover is provided with plurality of ribs that are disposed on the inner face and the ribs connect the peripheral wall with the port apertures providing structural rigidity to the cover. It is an advantage that the cover forms a light weight yet rigid structure for securing the master control unit securely to withstand the vibrations and other impacts.
[00036] It is a feature of the present subject matter that the housing assembly reduces load on the chassis. As, the board assembly can be slidably mounted to the chassis. This eliminates the need for mounting bosses on the chassis that are used for mounting the circuit assembly. Further, the covers through the stoppers act as load bearing members supporting circuit assembly.
[00037] It is yet an additional feature that the covers at least partially support the weight of the cables due to the cable connecting portions being disposed about the covers, whereby the heavy cables like power cables do not the joints on the boards.
[00038] It is yet another feature that the cover is provided with locking members disposed adjacent to the port aperture. The locking members are integrally formed with the cover provided to enable locking of the port in a defined position. It is an advantage that during assembly of cables to the port, torque/force applied on the cable that gets transfers to the port is restricted by the locking members from reaching the board.
[00039] It is another feature that the port includes a connector body and an adapter is provided between the connector body and the cover to provide tight seal. The adapter includes an abutting body that is having a surface area greater than the rest of the adapter, wherein a gasket made of an elastic material is disposed between the abutting body and the cover thereby compensating any gap thereat.
[00040] In one embodiment, the chassis includes a first opening provided on one side thereof, and a second opening provided on another side thereof. In a preferred embodiment, the one side is opposite to the another side. As per an embodiment, one side is geometrically different from another side. The first opening being securely sealed by a first cover that is provided with a port aperture to enable a first cable connecting portion to be accommodated thereat. Similarly, the second opening is securely sealed by a second cover that is provided with a port aperture to enable a second cable connecting portion to be accommodated thereat. Thus, the first cable connecting portion and the second cable connecting portion receive cables that have different function. For example, a power cable is connected to the first connecting portion and a signal cable/communication cable is connected to the second cable connecting portion.
[00041] The aforesaid and other advantages of the present subject matter would be described in greater detail in conjunction with the figures in the following description.
[00042] Fig. 1 illustrates a left side view of an exemplary motor vehicle 100, in accordance with an embodiment of the present subject matter. The vehicle 100 illustrated, has a structural member 105. In the present embodiment, the structural member is a step-through type structural member 105 that includes a head tube 105A, and a main frame 105B that extend rearwardly downward from an anterior portion of the head tube 105A. The main frame 105B extends inclinedly rearward to a rear portion of the vehicle 100.
[00043] The vehicle 100 includes an internal combustion engine 115 that is connected to the structural member 105. In the present implementation, the engine 115A is mounted on a swing arm 135, which is swingably connected to the main frame 105B using a toggle link. The vehicle 100 also includes a traction motor 120, which is another prime mover. In a preferred embodiment, the traction motor 120 is hub mounted to a rear wheel 125. A front wheel 110 is rotatably supported by the structural member 105. The front wheel 110 is connected to a handle bar assembly 130 that enables maneuvering of the vehicle 100.
[00044] The vehicle 100 includes a high capacity on-board battery (not shown) drives the traction motor 120. The high capacity battery can be disposed at a front portion or a rear portion of the vehicle 100. The high capacity battery is supported by the structural member 105 and the vehicle 100 includes plurality of body panels, mounted to the structural member and covering various components of the vehicle 100. The plurality of panels includes a front panel 140A, a leg shield 140B, an under-seat cover 140C, and a left and a right side panel 140D. A glove box may be mounted to a leg shield 140B.
[00045] A floorboard 145 is provided at the step-through portion defined by the main tube 105B. A seat assembly 150 is disposed rearward to the see-through portion and is mounted to the main frame 105B. One or more suspension(s) connect the wheels 110, 125 to the vehicle 100 and provide comfortable ride. The vehicle 100 comprises of plurality of electrical and electronic components including a headlight 155A, a taillight 155B, a starter motor (not shown), a horn etc. Also, the vehicle 100 includes a master control unit disposed in a housing assembly 200.
[00046] Fig. 2 depicts a perspective view of the housing assembly for the master control unit, in accordance with an embodiment of the present subject matter. The housing assembly 200 includes a chassis 205 and one or more covers 210, 215. The chassis 205 is made of a rigid material including metal. In the present implementation, the chassis 205 is made of Aluminium (Al) or an alloy with Aluminium being the major element and is preferably extruded part, which is easier to manufacture compared to casting. The covers 210, 215 are capable of sealing the open portions of the chassis 205 by using multiple fasteners 220. The covers 210, 215 are adapted to accommodate cable connecting portions 231, 232 therethrough, wherein at least a portion of the cable connecting portions 231, 232 are extending outward from the covers 210, 215.
[00047] In the depicted implementation, the housing assembly 200 includes two openings; a first cover 210 is disposed at one opening/first opening 205O1 of the chassis 205 whereby the first cover 210 covers the first opening 205O1. Another opening/second 205O2 of the chassis 205 is covered by the second cover 215 disposed on another side of the chassis 205. In the present implementation, the first cover 210 and the second cover 215 are disposed on opposite sides of the chassis 205. However, the position of the covers 210, 215 is not restricted to the positions as depicted in the present embodiment, as the cable connecting portions 231, 232 can be disposed at any side of the chassis 205. The preferred implementation as depicted in the present embodiment provides compact layout for the housing assembly 200 as the various cables having different functions or different operating parameters can be separated thereby separating one set of cables towards one side and another set of cables to another side.
[00048] In the depicted embodiment, the chassis 205 includes a base 205B and fin portion 205F. The fin portion 205F extends to the sides excluding the base 205B. In the present embodiment, the chassis has six sides with openings 205O1, 205O2 provided on two sides and the fin portion 205F extends to three sides of the chassis 205. The base 205B protrudes outward beyond the width of the fin portion 205F and the base 205B is provided with fastener apertures 221 for securing the housing assembly 200 to the structural member 105 of the vehicle 100. The housing assembly 200 is capable of securely accommodating the master control unit 225 (shown in Fig. 3) therein and restricts entry of dust, water, moist or the like.
[00049] Fig. 3 depicts an exploded view of the housing, in accordance with the embodiment of Fig. 2. The chassis 205 in the present implementation has a hollow region 205H with openings 205O1, 205O2 on either side, wherein the master control unit 225 is slidably mounted to the chassis 205 at the hollow region 205H. The master control unit 230 includes cable connecting portion(s) 231, 232 that extend from the chassis 205. A first cover 210 is provided on one side of the chassis 205 to cover the opening 205O1 thereat and a second cover 215 is provided on the other side of the chassis 205 to cover the opening 205O2 thereat. Further, gaskets 210G, 215G are provided between the covers 210, 215 and the chassis 205 to provide tight seal therebetween. In the present implementation, the covers 210, 215 are secured to the chassis 205 through fasteners 220.
[00050] In the depicted embodiment, the first cover 210 being adapted to accommodate one cable connecting portion 231 correspond to one cable type and other cable connecting portion 232 corresponding to another cable type is accommodated by the second cover 215 whereby the cable connecting portions are disposed away each other thereby the cables with different functional features that get connected to connecting portions 231, 232 are also disposed away from each other.
[00051] Fig. 4 depicts a perspective view of the master control unit, in accordance with the embodiment of Fig. 3. Fig. 5 depicts a cur-sectional view of the housing assembly. The master control unit 225 is slidably mounted to the housing assembly 200.The master control unit 225 is an electronic unit that includes plurality of printed circuit boards (PCBs) 230A, 230B that support switching electronic components 235 (shown in Fig. 7) like Metal oxide semiconductor field effect transistors (MOSFETs), Bipolar junction transistors (BJTs), or other semiconductor components. Further, the switching components 235 are in thermal contact with a cooling bar 240 (shown in Fig. 7) that is further in thermal contact with the chassis 205. Thus, the high heat dissipating elements are in thermal contact with the chassis 205 through the cooling bars 240. The cooling bars 240 are preferably chosen from metals with high thermal conductivity. Further, the chassis 205 includes plurality of fins 260 formed on the fin region 205F disposed annularly about outer surface of the chassis 205 and extending either along long axis of short axis thereof. The boards 230A, 230B as depicted in Fig. 4 are separated plenary thereby forming a gap therebetween to accommodate the electronic components 235.
[00052] The printed circuit boards 230A, 230B are collectively referred to as circuit board assembly 230 that forms the physical structure of the master control unit 225. Therefore, the terms board assembly 230 and master control unit 225 are interchangeably used. The circuit board assembly 230 includes cable connecting portion 231, 232 at least extending outward from the housing assembly 200 to enable connection of electrical wires/ports. The circuit board assembly 230 is slidably mountable to the chassis 205 through guiding slot 205G provided in the chassis (shown in Fig. 6). The chassis 205 is provided with plurality of slots that are symmetrically provided on the internal side and are provided on orthogonal sides to the direction of reception of the circuit board assembly 230.
[00053] The depicted master control unit 225/circuit board assembly 230 includes a first board 230A and a second board 230B that are physically connected to each other through one or more spacer(s) 255A, 255B that is disposed between the board 230A, 230B. The spacer(s) 255A, 255B also provides sufficient clearance to maintain sufficient gap between the boards 230A, 230B. In on embodiment, a sensor board 230C, which is referred to as a third board 230C, is disposed between the first board 230A and the second board 230B and is electrically connected thereto. The first board 230A is provided plurality of electronic components 235 (shown in Fig. 6) that are soldered thereof.
[00054] The electronic component 235 includes a body, contact legs - Source, Drain, and Gate, and a heat sink connecting portion (not shown). The electronic component 235 is soldered to the first board 230A by passing the legs through pads (not shown) provided on the first board 230A. The pads provide through holes for mounting the components likes electronic components 235 and other elements and also include electrical contact. The various pads are connected to each other in a defined pattern through traces provided on the first board 230A to establish electrical connection between the components. Further, the heat sink connecting portion of the electronic components 235 is connected to a metal bar 240 (shown in Fig. 7) that connects all the electronic components 235 disposed in a line or a pattern thermally. Further, a clip (not shown) is used to secure the metal bar and the electronic components 235. The first board 230A is also provided with a signal cable connecting portion, which is referred to as signal port/first cable connecting portion 232. Further, the board assembly 230 includes a second board 230B that is disposed at other end of the spacers 255A, 255B. The second board 230B is provided with power cable connecting portion, which are referred to as power studs/second cable connecting portion 231. The second cable connecting portion 231 are disposed on the side opposite to the side the first cable connecting portion 232 is disposed. Further, the first board 230A and the second board 230B are electrically connected to each other using detachable connectors 234. For example, the detachable connectors 234 can be Sam Tech connectors. The circuit board assembly 230 as a single unit is mountable to the chassis 205.
[00055] Fig. 6 depicts a perspective view of a portion of the master control unit 225 and a second cable connecting portion 231, in accordance with the embodiment of Fig. 4. The second board 230B is having pads that includes through holes 230BH selectively provided and are selectively connected through traces. The second cable connecting portion 231 are disposed on inward facing side of the second board 230B. The second cable connecting portion 231 are disposed at the end portion of the second board 230B and the secured to the board using fasteners 220. The power stud 231, in a preferred implementation, includes a body 231B having at least one flat side. Further, the power stud 231 includes an extended portion 231C that is capable of being connected to a power cable (not shown). In one implementation, the extended portion 231C includes hollow portion that is threaded whereby the power cable can be securely fastened to the power stud 231 whereby any loose connection is avoided. Also, the external surface of the extended portion 231C is provided with ridges 231R that are disposed annularly thereof.
[00056] Fig. 7 depicts a sectional view of the housing assembly taken along X-X’, in accordance with the embodiment of Fig. 2. Fig. 8 depicts a perspective view of the cover 210, in accordance with the embodiment of Fig. 2. The first cover 210 is secured to the opening provided on the chassis 205. A gasket 210G is disposed between the first cover 210 and the chassis 205. The first cover 210 is made a polymer material and the gasket 210G is made of an elastic material. The gasket 210G being made of elastic material accommodates any gaps between the first cover 210 and the chassis 205. Further, the first cover 210 is provided with protruded guides 213 that extending at the inward face thereof. Also, the gasket 210G is provided with cut-portion 212 that is provided to match the guide 213 whereby the gasket is located at the desired position even during assembly eliminating any misalignment. The cover 210 includes a peripheral wall 210P (shown in Fig. 9) that is having substantial thickness and the peripheral wall 210P runs about the periphery of the cover 210 at the inward face. The peripheral wall 210P abuts against the gasket 210G that further abuts the chassis 205. In one embodiment, the gasket 210Gincludes at least an L-shaped profile abutting two sides of the cover 210 providing secure sealing due to the sealing in two directions.
[00057] Further, the inward face of the cover 210 is provided with a stopper 214 for stopping linear movement of the boards mounted to the chassis 205. The boards 230A, 230B of the board assembly 230 are slidably mounted to the chassis 205 through opening of the chassis 205. Subsequently, the cover 210 is secured to the chassis 205 that securely seals the opening. Further, the stopper 214 aligns with the board 230A (as depicted in Fig. 7) whereby any further movement of the board 230A is restricted. In the presentation, implementation the stopper 214 is having a U-shaped section, wherein the board 230A/230B abuts in the opening of the U-shape and the opening is facing the board. Further, the cover 210 includes port apertures 210A that are provided to receive the extended portion 231C of the power stud 231. Further, plurality of O-rings 233 is provided between the ridges formed on the extended portion 231C of the power stud 231. Also, the O-rings 233 are preferably made of elastic material with the thickness greater than the height of the ridge 231R. Thus, in the assembled condition, the extended portion 231C of the power stud 231 is accommodated in the port aperture 210A and the O-rings 233 provide interference fit thereat. This provides tight seal avoiding entry of moist or water through the port aperture 210A.
[00058] Also, the power stud 231 extends partially outward from the cover 210 to enable connection of power cables. Further, the cover 210 is provided with cable guides 216 that are provided at end of the cover 210, preferably at the side from which the cables are routed. Further, the cover 210 is provided with inner ribs 217 that extend along at least a portion of the inner face of the cover 210. This provides the structural rigidity to the cover 210 to withstand the vibrations from the vehicle 100, to withstand the force from fasteners 220. Also, the second cover 215 is also selectively adapted with the aforementioned features.
[00059] Fig. 8 depicts another perceptive view of the cover of the housing assembly, in accordance with the embodiment of Fig. 7. The second cable connecting portion 231 that are secured to the board assembly 230 receive the high current carrying electrical cables. The cables are provided with a threaded portion that gets secured to the extended portion 231C of the power stud 231. The cover 210 is provided with locking members, which are locking walls 218 in the depicted implementation, disposed adjacent to the port aperture 210A that is a cylindrical guide. The locking walls 218 are provided to enable locking of the power stud 231 in a defined position. In one implementation, the locking walls 218 abut against the flat sides of the body 231B of the power stud 231 to effectively hold the port 231. In other words, the body 231B has at least one flat side that is in contact with the locking wall 218 which is also flat. Therefore, during assembling of the cable to the power stud 231 the rotational torque applied on the cable that gets transfers to the power stud 231 and then to the locking walls 218 whereby the locking walls 218 provide support to the power stud 231 to retain its orientation. Also, the torque is not transferred to the second board 230B. Thus, the second board 230B, which is a delicate PCB is protected from the effect of torque and the twisting on the power stud 231 by the locking walls 218. In one implementation, the locking walls 218 are a pair of walls disposed on either sides of the port aperture 210A. In another implementation, the locking walls 218 is formed by at least two walls that are connected and disposed orthogonal to each other to complement the profile of the body 231B of the power stud 231. Further, the inner ribs 217 are connecting disposed about the locking walls 218 to provide additional strength. Also, the cover is provided with mounting through holes 270 that enables securing of the cover 210 to the chassis 205. The outer face of the cover 210 is provided with labels adjacent to the extended portions 231C of the power stud 231 to provide identification of cables mounting portions. For example, the phase related labels like ‘R’, ‘B’, and ‘Y’ are marked adjacent to their respective locations.
[00060] Fig. 9 depicts an exploded view of the signal port and cover, in accordance with the embodiment of Fig. 2. The first cable connecting portion 232 includes a connector body 232B that is soldered to the first board 230A (as shown in Fig 4). The connector body 232B is further provided with an adapter 232A, wherein the adapter 232A is mounted to the connector body 232B. The adapter 232A includes an abutting body 232AA that is having a surface area greater than the rest of the adapter 232A. In other words, an end portion of the adapter 232A that is in proximity to the second cover 215 is having abutting body 232AA that is extending annually outwards. The second cover 215 is provided with a port aperture 215A and the abutting body 232AA abuts the inner face of the second cover 215 such that the connecting pins of the connector body 232B are accessible through the port aperture 215A. Further, a gasket 215G made of an elastic material is disposed between the abutting bod y 232AA and the cover so that any gap between the cover 215 and the adapter 232A is compensated by the gasket 215G. The second cover 215 is also made of a polymer material and is disposed at the other opening of the chassis 205.
[00061] Many modifications and variations of the present subject matter are possible in the light of claims herein. It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein.

List of reference signs:

100 vehicle
105 structural member
105A head tube
105B main frame
115 internal combustion engine
120 traction motor
125 rear wheel
130 handle bar assembly
135 swing arm
140A front panel
140B leg shield
140C under-seat cover
140D side panel
145 floorboard
150 seat assembly
155A headlight
155B taillight
200 housing assembly
205 chassis
205B base portion
205F fin portion
205G guiding slot
205H hollow region
210/215 cover
210A/215A port aperture
210G/215G gasket
210P peripheral wall
212 cut-portion
213 protruded guide
214 stopper
216 cable guides
217 ribs
218 locking walls
220 fastener
225 master control unit
230 circuit board assembly
230A first board
230B second board
230BH through holes
230C third board
231 second cable connecting portion
231C extended portion
231R ridges
232 first cable connecting portion
232A adapter
232AA abutting body
232B connector body
233 O-ring
234 connectors
235 electronic component
240 cooling bar
250B second end
255A\
255B spacers
260 plurality of fins
270 through holes
,CLAIMS:We claim:
1. A housing assembly (200) for mounting to a motor vehicle (100), said housing assembly (200) comprising:
a circuit board assembly (230);
a chassis (205) including at least one opening (205O1, 205O2) and said chassis (205) capable of slidably receiving and supporting said circuit board assembly (230) through at least one opening (205O1, 205O2);
one or more cover(s) (210, 215) detachably secured to said chassis (205), and said one or more cover(s) (210, 215) capable of securely sealing said at least one opening (205O1, 205O2) of said chassis (205), said at least one cover (210, 215) being adapted to accommodate a first cable connecting portion (232) and a second cable connecting portion (231), said- first cable connecting portion (232) corresponding to a first-type of cable(s), and a second cable connecting portion (231) corresponding to a second-type of cable(s), said second-type of cable(s) being different from said first-type of cable(s), and said first cable connecting portion (232) disposed away from said second cable connecting portion (231).
2. The housing assembly (200) as claimed in claim 1, wherein said chassis (205) being made of a rigid material having high thermal conductivity and at least one cover of said one or more cover(s) (210, 215) is made of a polymer, and at least one gasket (210G, 215G) sandwiched between the cover (210, 215) and said chassis (205), and said gasket (210G, 215G) includes at least an L-shaped profile abutting two sides of said cover (210, 215) providing secure sealing.
3. The housing assembly (200) as claimed in claim 1, wherein said chassis (205) includes a first opening (205O1) provided on one side thereof, and a second opening (205O2) provided on another side, said another side being geometrically different from said one side, said first opening (205O1) being securely sealed by a first cover (210) of said one or more cover(s) (210, 215), said second opening (205O2) being securely sealed by a second cover (215) of said one or more cover(s) (210, 215), and said first cover (210) adapted to accommodate said first cable connecting portion (232) and said second cover (215) adapted to accommodate said second cable connecting portion (232).
4. The housing assembly (200) as claimed in claim 1, wherein said circuit board assembly (230) includes one or more board(s) (230A, 230B, 230C), a first board (230A) of said one or more board(s) (230A, 230B) disposed planar separately from a second board (230B) of said one or more board(s) (230A, 230B), said first board (230A) being provided with said first cable connecting port (232) and said second board (230B) being provided with said second cable connecting port (232), and at least one of said first cable connecting port (232) and said second cable connecting port (232) is extending outward from a port aperture(s) (210A, 215A) provided on corresponding said cover (210, 215) thereof.
5. The housing assembly (200) as claimed in claim 1, wherein said one or more cover(s) (210) is provided with one or more locking members (218) disposed adjacent to a port aperture (210A), and said locking members (218) abut against a body (231B) of the port (231) in an assembled condition of said cover (210, 215) to said chassis (205) to effectively hold the port (231).
6. The housing assembly (200) as claimed in claim 1, wherein said cover (210, 215) includes a peripheral wall (210P) extending along at least a periphery thereof abutting a gasket (210G, 215G) against said chassis (205), and said cover (210, 215) includes a protruded guide (213) passing through a cut-portion (212) of said gasket (210G) thereby holding said gasket (210G) in a desired location.
7. The housing assembly (200) as claimed in claim 4, wherein said port aperture (210A) is a cylindrical portion and said second cable connecting portion (231) includes an extended portion (231C) provided with plurality of ridges (231R) annularly disposed thereof, and plurality of O-rings (233) made of elastic material are disposed between adjacently disposed ridges (230R), and said extended portion (231C) disposed about the port aperture (210A) thereby providing tight seal.
8. The housing assembly (200) as claimed in claim 1, wherein said cover (210, 215) includes one or more stopper(s) (214) provided on inner side of said cover (210, 215) and said one or more stopper(s) (214) aligning with one or more board(s) (230A, 230B, 230C) of a board assembly (230) capable of supporting and restricting movement of the board assembly (230) being slidably mounted to said chassis (205), and wherein said stopper (214) includes a U-shaped profile.
9. The housing assembly (200) as claimed in claim 1, wherein said cover (210, 215) includes plurality of ribs (217) extending along at least a portion one inner side thereof, and wherein said ribs (217) are connected to said walls (218) and to said peripheral wall (210P) providing structural rigidity.
10. The housing assembly (200) as claimed in claim 1, wherein said cover (215) abuts against an adapter (232A) being mounted to a connector body (232B) of said first cable connecting portion (232), and said adapter (232A) includes an abutting body (232AA) for abutting against said cover (215) with a gasket (215G) disposed therebetween for providing a tight seal thereat.