DESC:Field of the Invention
This invention, in general relates to the field of automotive. In particular, the present invention provides an integrated electric drive kit and method for converting Internal Combustion (IC) engine driven locomotive to electric drive using the said Kit.

Background of the Invention
The history of transportation has gone through various phases and evolved in different ways. In 20th century internal combustion engine came in bigger way. Now days there are huge challenges of global warming and whole world is working to avoid such situation. This leads to the improving transport system to avoid carbon emission in the environment. Various design has been developed to make alternative of the internal combustion engine.

Various kits have been developed to improve the transportation, however, the currently available conversion kits are limited in numbers. It also lacks in ease in replacement of IC engine with electric kit because of complexity involved in overall system architecture. Available choices are generally falls in bigger vehicle category and is limited to only motor, controller and drive.

Further, the existing conversion kits to convert the IC engine powered vehicles into Electric are not designed to fit in and effective for light motor vehicles for e.g. autos, rickshaws and three wheelers. Also, the overall weight, size and performance do not match the requirements.

Light motor vehicles are one of the important transport system in many countries around the world, specially developing and under developed countries. Replacing IC engine with electric drivetrain can provide a huge contribution in the transport system.

It would be desirable, therefore, to provide an apparatus, system and method which is designed and developed in a manner to overcome the drawback associated with the prior arts and adaptable in effective use in light motor vehicles frame.

Objects and Summary of the Invention
It is an advantage of the invention to provide a solution of developing an integrated electric drive kit which enable to save fuel, reduced engine noise, no emissions and it is also reliable and safe hence obviates the challenges exists in the current IC engine.

It is a principle objective of the present invention to provide a solution of developing an integrated electric drive kit which enable to reduce pollution or carbon footprint in overall lifecycle of vehicle, wherein said Kit is concise and easy to assemble.

The particular invention is the aggregate of various electro-mechanical elements for converting the existing auto rickshaw vehicles with IC engine and associated accessories to operate on stored battery energy.

According to one of the objective of the present invention is to provide integrated electric drive kit which enable conversion from IC Engine to Electric drive, wherein said electric powertrain kit with onboard charger.

Another objective of the present invention to provide a kit enabling conversion from IC Engine to Electric drive, wherein said kit is having compact in orientation and easier to fit.

The above and other objects are achieved in accordance with following embodiments of the present invention, wherein the invention is achieved by designing an integrated electric drive kit which is adapted to employ in low powered vehicle. However, the present invention is not limited to the preferred embodiments described herein below.

In accordance with a preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit.
In accordance with another preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit and wherein said Kit further comprising an electric converter mounted above the gearbox and motor, wherein the electric converter is configured to convert a high voltage power into a low voltage power.

In accordance with another preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit and wherein said Kit comprising a heat sink for efficient cooling of the motor controller and the electric converter.

In accordance with another preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit and wherein said Kit, and wherein the motor controller is mounted above the gearbox.

In accordance with another preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit and wherein said the one or more gearbox output shafts comprises flange cups and wherein the flange cups are coupled to propeller shafts for transmitting power to wheels of the vehicle.

In accordance with a preferred embodiment of the present invention, there is provided an integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising a gearbox comprising one or more gearbox output shafts, a motor mounted on the gearbox and comprising a motor shaft directly coupled to the gearbox, a motor controller coupled to the motor, the motor controller configured to control the motor, a battery coupled to the motor controller, the battery configured to supply energy to the motor and a charger mounted opposite to the motor across the gearbox and electrically connected to the battery, the charger configured to supply a charging current to the battery, wherein the gearbox, the motor, the battery, and the charger are assembled into a single unit, wherein said kit further comprising gearbox mountings, and wherein the gearbox mountings are configured to be mounted on cross bars of a frame of the vehicle.

The integrated electric drive kit according to the present invention is mountable on a vehicle frame cross bar and wherein said kit is capable of being mounted in a rear wheel or front wheel drive configuration.

These and other objectives and embodiments of the invention will become more fully apparent when the following detailed description is read with the accompanying figures and examples. However, both the foregoing summary of the invention and the following detailed description of it represent one potential experiments and embodiment and are not restrictive of the invention or other alternate embodiments of the invention.

Brief Description of the Accompanying Drawings
The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

Figure 1 illustrates a top view of the integrated electric drive kit
Figure 2 illustrates integrated electric drive kit side view arrangement with wheel and frame
Figure 3 illustrates auto rickshaw frame with integrated electric drive kit
Figure 4 illustrates components of integrated electric drive kit
Figure 5 illustrates integrated electric drive kit positioned in light motor vehicles frame

Detailed Description of the Invention
The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

Various terms as used herein in the invention is not defined and it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

Embodiments of the present disclosure generally relate to a Kit and a method for converting Internal Combustion (IC) engine driven locomotive to electric drive using the said Kit. According to the present invention, the disclosed kit implements easy conversion procedure in which internal combustion engine is towed down from its position and replaced by electric kit with bolt on replacement. All the mechanical connection like propeller shaft and CV (constant velocity) joint are replaced with structurally same but upgraded arrangement for proper fitment and efficient power transmission. Kit is having own wiring harness which replaces all auxiliary connection that were required to operate IC engine, wiring harness have simplistic approach having only two connectors, one is auxiliary connector which take care of supply to all lighting, dash board controls, communication protocols and battery auxiliary connection and other one is main battery supply connector (power connector).
Although various embodiments of the present disclosure have been described with reference to overcome the technical problem with the design of existing engine like unavailability of generalized solution for utilizing it in cost-effective manner for masses, meeting performance parameters, Packaging requirements, and ease in mounting and quick conversion. Most importantly does not able to cater to low powered vehicles conversion (<30 kW). This can be in essence, the design of the current Kit should be such that enabling conversion from IC Engine to Electric drive, wherein said integrated electric drive kit with onboard charger. Also, the kit is specifically designed keeping small vehicles such as autos, rickshaws and three wheelers however it is not limited and can also be further extended to light motor vehicles or any other desired vehicles.

According to the present invention, the purpose, in general, to provide a kit enabling conversion from IC Engine to Electric drive, wherein said kit is having compact in orientation and easier to fit in the low powered vehicle, wherein said kit is having improved ingress protection and all auxiliary components along with powertrain and wherein said Kit is providing innovative cooling system by utilising motor exhaust fan to create air flow current around controller heat sink. Said motor herein utilises centrifugal fan having advantage of same direction of air flow irrespective of direction of rotation. Air flow in motor happens to be from front opening to rear exit while operational. By utilising this forced air flow, an air current is created with the help of enclosure and specific opening position near controller heat sink. A cold air is sucked from provided opening near heat sink of controller which flow over fins structure carrying generated heat by controller while operational to the motor inlet vents and then exit to surrounding. Motor always work at elevated temperature than controller hence making system logical in operation with this phenomenon.

According to the present invention, there is provided a very easy mounting solution cater to low powered vehicles for example rickshaw and other desired vehicle where the whole kit is a single unit which includes all the components required to convert the IC engine powered locomotive into Electric drive, wherein said kit is having innovative cooling system by utilizing motor exhaust fan to create air flow current around controller heatsink.

According to the present invention, the kit disclosed herein is mountable on vehicle frame cross bar.

Integrated Electric Drive Kit disclosed herein according to the present invention contains Motor, Motor controller, Battery (as a source of energy), Gear box and differential as critical components. Further, charger and DC-DC converter is provided for the auxiliary functioning of the powertrain and the vehicle.

Referring figure 1 shows the components which together forms the electric powertrain system of the Electric drive kit. Here the motor (3) shaft is directly coupled to the gear box input and is mounted on the gear box (5) itself. The gearbox (5) here performs two functions including speed reduction and the differential action for the rear wheels. Speed reduction is important for the kit so as to run the motor in the efficient speeds while the wheels get the maximum torque required and Differential for the vehicle to negotiate the corners smoothly and effectively. The kit also constitutes of the charger (4) which is mounted opposite to the motor across the gear box as shown in Figure 1. The charger is provided onboard for ease of charging on the go for the vehicle.

The motor controller (1) and the DC-DC converter (2) are mounted above the gear box and motor. The mountings are provided such that their base is made up of Heat sink (17) for efficient cooling of the controller and DC-DC Converter as they produce considerable amount of heat during peak power requirement. Openings for the air flow through the motor and charger are also provided for cooling. The gearbox output shafts constitute of flange cups (6&7) for the power transmission to the wheels through the propeller shafts (15&16) which together for a constant velocity joint. Power cables run from motor to controller and cables from controller to the connector for battery. The kit is held by the gearbox mountings (8&9) which are mounted on the cross bars of the Auto rickshaw frame. The propeller shafts drive the wheels through the flange cups attached to the wheels. Placing the components in the given orientation yields with compact packaging and easy of wiring within the powertrain system. Also, by this kind of packaging the user will find the E propulsion kit simpler and safer. This design of the E propulsion kit makes mounting and dismounting and conversion from IC Engine to Electric drive easier and simpler.

Further, as shown in figure 5, the complete kit is mounted in the auto rickshaw chassis as a single unit in the space defined by the respective manufacturers for the IC engine. During the conversion, the exiting IC engine is removed, and the electric conversion kit is mounted in the engine space. The kit is already provided with the flange cups (6) & (7) for the propeller shaft to drive the wheels. The kit includes motor, controller, Electric converter, charger and complete circuitry. The motor controller draws the electric energy stored in the battery (removable or non-removable type) which connects to the conversion kit by a single connector. Controller drives the motor to perform as per the driver requirements based on the inputs given on the throttle and the brakes. The motor is coupled to the gear box within the kit where the speeds and torque of the motor is converted into required speed and torque for the wheels. The gear box also performs the differential action required by the vehicles. This is required for the vehicle to maneuver the corners with ease. The differential ends are fitted with the flange cups which drive the wheels through the propeller shafts. The kit also include charger inbuilt for the connected battery for charging on the go. The charger provided onboard eliminates the effort of handling and connecting the external charger. There is also electric (DC) converter provided in the kit which converts the high voltage power into lower voltage for the vehicle electronics to work. Also, the kit is provided with natural air cooling system for the electronic components which heat up while normal functioning of the kit.

Various terms as used herein are shown below. To the extent a term used in a disclosure is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing. Further this concept can be extended to any Electric Vehicles, Battery electric vehicle, Electric powertrain vehicles, Electric conversion kit, Electric Propulsion kit, Electric powertrain Kit.

The embodiments in the specification are described in a progressive manner and focus of description in each embodiment is the difference from other embodiments. For same or similar parts of each embodiment, reference may be made to each other.

While the invention is amenable to various modifications and alternative forms, some embodiments have been illustrated by way of example in the drawings and are described in detail above. The intention, however, is not to limit the invention by those examples and the invention is intended to cover all modifications, equivalents, and alternatives to the embodiments described in this specification.

It will be appreciated by those skilled in the art that the above description was in respect of preferred embodiments and that various alterations and modifications are possible within the broad scope of the appended claims without departing from the spirit of the invention with the necessary modifications.

Based on the description of disclosed embodiments, persons skilled in the art can implement or apply the present disclosure. Various modifications of the embodiments are apparent to persons skilled in the art, and general principles defined in the specification can be implemented in other embodiments without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is not limited to the embodiments in the specification but intends to cover the most extensive scope consistent with the principle and the novel features disclosed in the specification. ,CLAIMS:We Claim:
1. An integrated electric drive kit for a vehicle, the integrated electric drive assembly comprising:
a gearbox (5) comprising one or more gearbox output shafts;
a motor (3) mounted on the gearbox (5) and comprising a motor shaft directly coupled to the gearbox;
a motor controller (1) coupled to the motor, the motor controller (1) configured to control the motor;
a battery coupled to the motor controller (1), the battery configured to supply energy to the motor; and
a charger (4) mounted opposite to the motor (3) across the gearbox (5) and electrically connected to the battery, the charger configured to supply a charging current to the battery,
wherein the gearbox (5), the motor (3), the battery, and the charger (4) are assembled into a single unit.

2. The integrated electric drive kit as claimed in claim 1, wherein said Kit further comprising an electric converter (2) mounted above the gearbox (5) and motor (3), wherein the electric converter (2) is configured to convert a high voltage power into a low voltage power.

3. The integrated electric drive kit as claimed in claim 1, wherein said Kit further comprising a heat sink (17) for efficient cooling of the motor controller (1) and the electric converter (2).

4. The integrated electric drive kit as claimed in claim 1, wherein the integrated electric drive kit is mountable on a vehicle frame cross bar.

5. The integrated electric drive kit as claimed in claim 1, wherein the motor controller (1) is mounted above the gearbox (5).

6. The integrated electric drive kit as claimed in claim 1, wherein the one or more gearbox output shafts comprises flange cups (6, 7).

7. The integrated electric drive kit as claimed in claim 6, wherein the flange cups (6, 7) are coupled to propeller shafts (15, 16) for transmitting power to wheels of the vehicle.
8. The integrated electric drive kit as claimed in claim 1, further comprising gearbox mountings (8, 9), wherein the gearbox mountings (8, 9) are configured to be mounted on cross bars of a frame of the vehicle.

9. The integrated electric drive kit as claimed in claim 8, mounted in a rear wheel drive configuration.

10. The integrated electric drive kit as claimed in claim 8, mounted in a front wheel drive configuration.

11. The integrated electric drive kit as claimed in claim 1, wherein said kit is capable of employing in low powered vehicle
.
12. The integrated electric drive kit as claimed in claim 1, wherein said kit is enclosed with enclosure (18).

13. The integrated electric drive kit as claimed in claim 1, wherein said kit comprises of motor (3) with fan.