Claims:I/We Claim:

1. A vehicle (100) comprising:

a traction motor (102) mounted on an axle of a wheel (101),
a swing arm (105) comprising at least one swing arm portion (105a) for holding the axle of the wheel 101 firmly;
at least one storage frame (107 and 108) for holding one or more electrical components (104 and 106) in the vehicle (100); and
a terminal cable (103) routed from the traction motor (102) to the one or more electrical components (104 and 106) supplying at least one of a power signal and a control signal to the traction motor (102) along a length of the vehicle (100) using a cable routing structure (111).

2. The vehicle (100) as claimed in claim 1, wherein the cable routing structure (111) comprises:

at least one clamper (600) for securing the terminal cable (103) to the at least one swing arm portion (105a) and the at least one storage frame (107 and 108) to prevent damage to the terminal cable (103), and
at least one holding provision (301, 401, and 501) at at least one holding location (302, 402, and 502) of each of the at least one swing arm portion (105a) and the at least one storage frame (107 and 108) to engage with each of at least one of clampers (600).

3. The vehicle (100) as claimed in claim 1, wherein the one or more electrical components (104 and 106) comprise at least one battery module (104) for driving the vehicle (100), at least one control unit (106) for controlling the operation of the vehicle (100).

4. The vehicle (100) as claimed in claim 2, wherein the at least one holding location (302) of the at least one holding provision (301) on the at least one swing arm portion (105a) is centrally located on the at least one swing arm portion (105a) for preventing the terminal cable (103) from swinging loosely.

5. The vehicle (100) as claimed in the claim 2, wherein the at least one holding location (402 and 502) of the at least one holding provision (401 and 501) on the at least one storage frame (107 and 108) is located on one of a front surface, a rear surface, and a side surface of the at least one storage frame (107 and 108) for securing the terminal cable (103).

6. The vehicle (100) as claimed in claim 2, wherein encompassing profile of the at least one of the clampers (600) is one of a substantial circle, a substantial rectangle, a substantial triangle, a substantial trapezoid, and a substantial square.

7. The vehicle (100) as claimed in claim 2, wherein each of the plurality of clampers (600) comprises:
an extension member (601) that removably engages with the holding provision (301, 401, and 501).at the holding location (302, 402, and 502),
a strap (602) extending upwards from the extension member (601) for accommodating the terminal cable (103), and
a locking member (603) extending from the strap (602) and removably engaging in a slit (606) formed in the strap (602) for forming a tight looping profile to hold the terminal cable (103) at the holding location (302, 402, and 502).

8. The vehicle (100) as claimed in claim 7, wherein the each of the plurality of clampers (600) further comprises a retainer (604) for preventing exertion of stress on the strap (602).

9. A cable routing structure (111) for routing a terminal cable (103) in a vehicle (100) comprising:

at least one clamper (600) for securing the terminal cable (103) to at least one swinging portion (105a) and at least one storage frame (107 and 108) in the vehicle (100) to prevent damage to the terminal cable (103), and
at least one holding provision (301, 401, and 501) at one or more holding location (302, 402, and 502) of each of the at least one swinging portion (105a) and the at least one storage frame (107 and 108) to engage with at least one clamper (600),

wherein the at least one clamper (600) comprises:
an extension member (601) that removably engages with the holding provision (301, 401, and 501) at the holding location (302, 402, and 502);
a retainer (604) extending upwards from the extension member (601) for preventing exertion of stress on the strap (602);
a strap (602) extending upwards from the retainer (604) for accommodating the terminal cable (103); and
a locking member (603) extending from the strap (602) and removably engaging in a slit (606) formed in the strap (602) for forming a tight loop to hold the terminal cable (103) at the holding location (302, 402, and 502).

10. The cable routing structure (111) of claim 9, wherein the terminal cable (103) originates from a traction motor (102) mounted on an axle of a rear wheel (101) of the vehicle (100) and extends up to one of the at least one storage frame (107 and 108) via the at least one swing arm portion (105a).
, Description:TECHNICAL FIELD
[0001] The present subject matter relates to an electric vehicle. More particularly, to routing of cables of a traction motor in the electric vehicle.

BACKGROUND
[0002] With depletion of fossil fuel and increase in air pollution, need for an electric vehicle has increased rapidly. While providing a more efficient transportation solution, the last few years have seen a sudden increase in research and development activity in the areas of electric propulsion in various modes of transportation. One of which is a two-wheeled vehicle which calls for compact packaging of all electrical and electronic components. The electrical and electronic components may be located distant from each other along the length of the vehicle and the interconnecting wires between the electrical and electronic components in such a vehicle needs to be run along the length of the vehicle. However, the interconnecting wires needs to be routed without undergoing any damage due to stress because of the compact arrangement of the electrical and the electronic components in the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description is described with reference an embodiment of a saddle type vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0004] Fig. 1 exemplarily illustrates a partial left side perspective view of the vehicle showing routing of a terminal cable;
[0005] Fig. 2 illustrates a sectional view of a mounting of the traction motor on the axle of the rear wheel;
[0006] Fig. 3 exemplarily illustrates a first holding provision at a first holding location of the vehicle;
[0007] Fig. 4 exemplarily illustrates a second holding provision at a second holding location of the vehicle;
[0008] Fig. 5 exemplarily illustrates a third holding provision at a third holding location of the vehicle; and
[0009] Figs. 6A-6B exemplarily illustrate a clamper in different positions for holding the terminal cable at the first holding location, the second holding location and the third holding location of the vehicle.

DETAILED DESCRIPTION OF THE INVENTION
[00010] Electric vehicles comprise hub motors that are incorporated into the hub of the wheels. The hub motors may be in three configurations- an axial-flux motor, an inner rotation motor, and an outer rotation motor. In outer rotation motor, the hub motors have a rotating outer housing and a stationary shaft. That is, the magnets are rotating and the windings are stationary. Such hub motors have an array of permanent magnets on an inside surface of the hub. Stator windings are attached to the axle of the wheel. The hub rotates when alternating currents (AC) passes through these windings.

[00011] Since the windings are stationary, permanent connections to energize the windings is possible. The windings have terminal wires that include power lines and signal lines. The signal lines carry control signals to control the operation of the hub motor from a control unit of the vehicle. The power lines carry the required current to drive the hub motor from a battery module of the vehicle. The control unit and the battery module may be located at a position distant from the hub motor and thus, the terminal wires with an insulation are to be routed from the hub motor along longitudinal direction of the vehicle. These terminal wires are routed separately through the shaft of the wheel towards the control unit and the battery module avoiding close proximity to low voltage wiring harness of the vehicle.

[00012] However, design of the chassis of the vehicle may require the terminal wires to be bent, constricted, subjected to vibrations, abrasions, moisture, etc. The terminal wires with the insulation, hence forth referred to as terminal cable may be exposed to sharp edges of frame, undergo constant rubbing with swing arm of the vehicle, leading to early wearing of the terminal wires.

[00013] This type of damage to the terminal cable may lead to short circuiting between the terminal wires or short circuiting between the terminal wires and vehicle frame, leading to arcing. This damage to the terminal cable and the damage to the vehicle is intensified when the damaged terminal cable comes in contact with water. In such a situation, due to the damaged terminal cable, water entry into the insulation may occur, leading to rusting and winding degradation inside motor. The signal lines are even thinner than the power lines of the motor and if the signal lines get damaged due to damage to the terminal cable, the vehicle may become immobile as well as the control unit will not be able to excite motor phases.

[00014] In existing implementations, in order to hold the terminal cable along with the wiring harness, along length of the vehicle, cable ties are being used. However, the cable ties may not hold the terminal cable in place and prevent the terminal cable from moving, while the vehicle is in motion. Further, in conventional cable clamps that hold the terminal cable and fix it on to the chassis of the vehicle, a locking portion of the clamp may be easily unlocked, when an unlock lever extending outward is accidentally hit or excessive inertia forces act on the lock leaving known solutions unreliable. The vicinity of the swing-arm involves considerable dynamic movements of the vehicle aggregates which potentially can lead to undesirable fouling of the harness with nearby parts. Also, the harness needs certain portions of it to be permitted to be free to accommodate the compliance movement requirement between static & dynamic parts while still being secure & stable during usage of the vehicle. The open portion of the terminal cable is often vulnerable to whipping movements which makes cable routing very challenging to achieve a safe, secured, and stable routing. Also, from a manufacturer’s point of view, there exists a need to have flexibility of the diameter of the wiring harness which may vary depending on the voltage rating, number of wires routed etc. Thus, for a given layout platform of vehicle, the manufacturer may prefer to operate with multiple variants in form of power of the vehicle, features etc. requiring different diameters of the harness & cable to be adaptable by the routing.

[00015] Therefore, there exists a need for a reliable, adaptable, and stable routing of a terminal cable of the hub motor of the vehicle, while protecting cable integrity.

[00016] With the above objective in view, this invention discloses routing of terminal cable of the traction motor along the length of the vehicle. Another objective of the invention is to protect the terminal cable from wear due to vibration, shock, humidity, contact with the edges of the frames, while being routed from the motor to the control unit and the battery module. It is another object of the invention to identify multiple holding locations along the length of the vehicle from the front to the rear to hold the terminal cable in place in a stable manner. The holding locations are identified to avoid rubbing of the terminal cable with parts in the vehicle that experience more vibration shock, dust, humidity, dust, etc. to avoid rupture of the terminal cable and the terminal wires within thereby, resulting in a reliable routing configuration. An objective of the invention is to provide holding provisions at the holding locations that are strong and tight to hold the terminal cable in place, without stressing the terminal cable. Also, the holding provisions at the identified holding locations provide ease in assembly, reducing man-hours of assembly of the vehicle, and ease in serviceability of the vehicle.

[00017] Summary provided above explains the basic features of the invention and does not limit the scope of the invention. The nature and further characteristic features of the present invention will be made clearer from the following embodiment & description made with reference to the accompanying drawings.

[00018] The present subject matter disclosed herein relates to a traction motor wire routing in a vehicle. In an embodiment, the vehicle may be a two-wheeled vehicle or a three wheeled vehicle. In an embodiment, the vehicle may be an electric vehicle or a hybrid electric vehicle. More specifically, the present subject matter discloses routing of a terminal cable through holding provisions at holding locations in a saddle type vehicle to avoid wear tear of terminal cable and reduce the stress on the terminal cable.

[00019] As per an embodiment of the present invention, a vehicle with a cable routing structure is disclosed. The vehicle comprises a traction motor mounted on an axle of a wheel, a swing arm with one or more swing arm portions for holding the axle of the wheel firmly, and one or more electrical components held in at least one storage frame. A terminal cable routed from the traction motor to the electrical components for supplying at least one of a power signal and control signal to the traction motor. The terminal cable extends along the longitudinal direction of the vehicle from the rear of the vehicle to the front of the vehicle through a cable routing structure. As per another aspect of the present invention the terminal cable can be a high voltage harness or a low voltage harness for the vehicle.

[00020] The cable routing structure comprises at least one clamper for securing the terminal cable in a stable manner to the at least one swing arm portion and the at least one storage frame, at least one holding provision engaging with the clampers at at least one holding location of each of the at least one swing arm portion and the at least one storage frame. The clampers prevent damage to the terminal cable thereby ensuring reliability during assembly as well as usage.

[00021] The vehicle comprises a frame extending along a vehicle longitudinal direction, and a front wheel and a rear wheel supported by the frame. A drive system, such as, a hub motor is configured to provide a driving force to the rear wheel. The panels, such as the front panel, the rear panel, and the side panels on the left and right side of the vehicle are attached to the frame and enclose the electrical and electronic components, such as, battery modules, control units, telematics module, etc. The wiring harness of the vehicle and a terminal cable of the vehicle are also enclosed by the side panels of the vehicle.

[00022] Fig. 1 exemplarily illustrates a partial left side perspective view of a two wheeled saddle type vehicle 100 showing routing of a terminal cable 103, with the panels of the vehicle 100 removed. The terminal cable 103 exits from the hub motor 102 and runs along the length of the vehicle 100 towards the electrical components, such as, a battery module 104 and a control unit 106 of the vehicle 100 through a cable routing structure 111. As exemplarily illustrated, the hub motor 102 is mounted on the axle of the rear wheel 101 of the vehicle 100. The rear wheel 101 of the vehicle 100 is supported by a swing arm 105. The swing arm 105 includes two swing portions- a left swing arm portion 105a and a right swing arm portion 105b. As per an alternate embodiment, the vehicle 100 may have a swinging engine with a swinging portion 105a in place of the swing-arm. Also, one or more battery modules 104 and one or more control units 106 are positioned in the front or in the middle of the vehicle 100. In an embodiment, the hub motor 102 is mounted on the axle of the front wheel (not shown) of the vehicle 100, based on the traction required. Each of the battery modules, such as, 104 and the control units 106 is positioned in one or more storage frames, such as, 107 and 108.

[00023] As exemplarily illustrated, the battery module 104 is positioned in a storage frame 107 and the control units 106 are positioned in another storage frame 108. The material of the storage frames 107 and 108 is plastic, metal, carbon fiber, and any combination thereof. The terminal cable 103 originates from the traction motor 102 on an axle of the rear wheel 101 of the vehicle and extends up to a storage frame 108 of the control units 106 via the swing arm portion 105a. The terminal cable 103 when exiting from the motor shaft of the hub motor 102 is routed along the swing arm portion 105a of the vehicle 100 and runs diagonally along the inside of a frame 109 of the vehicle 100. A utility box area 110 is defined under a seat of the vehicle 100. The storage frame 107 for the battery module 104 and the storage frame 108 for the control units 106 are in front of the utility box area 110. As exemplarily illustrated, the terminal cable 103 is routed adjacent to the utility box area 110 till the control units 106 for phase wire connection through at least one cable routing structure 111. The cable routing structure 111 includes at least one clamper to secure the terminal cable 103 to the swing arm portion 105a and the storage frames 107 and 108. At least one holding provision at at least one holding location on each of the swing arm portion 105a and the storage frames 107 and 108 engages with the clampers. Each of the storage frames 107 and 108 and the swing arm portion 105a comprise a holding location and a holding provision at the holding location for holding the terminal cable 103, when the terminal cable 103 is routed as exemplarily illustrated in Figs. 2-4.

[00024] A first holding provision 301 is, thus, provided on the swing arm portion 105a of the vehicle 100 at a first holding location 302 as exemplarily illustrated in Fig. 3. A second holding provision 401 is provided on the storage frame 107 of the battery module 104 at a second holding location 402 as exemplarily illustrated in Fig. 4. A third holding provision 501 is provided on the storage frame 108 of the control units 106 at a third holding location 502 as exemplarily illustrated in Fig. 5. As per an embodiment at least any one of the holding locations 302, 402 & 502 may be implemented with partial compromises in the stable routing of the harness or cables. At each of the first holding location 302, the second holding location 402, and the third holding location 502, a clamper 600 as exemplarily illustrated in Figs. 6A-6B, engages with the first holding provision 301, the second holding provision 401, and the third holding provision 501, respectively. The clampers 600 secure the terminal cable 103 to the swing arm portion 105a and the storage frames 107 and 108 to prevent damage to the terminal cable 103. The separate clamper 600 enables flexibility & adaptability for a manufacturer to permit variations in the cable or harness diameters to be routed for different variants, markets etc.

[00025] Fig. 2 illustrates a sectional view of a mounting of the traction motor 102 on the axle of the rear wheel 101. A wheel assembly with tubeless tyre or a wheel assembly mounted over a periphery of a wheel rim. The trailing arm 105 also referred to as a swing-arm having a front end 105F and a rear end 105R is pivotally or fixedly attached to the frame 109 of the vehicle 100. The rear end 105R of swing arm 105 is connected to the rear wheel 101 and the front end 105F of the trailing arm 105 is connected to the frame 109. The prime mover is the traction motor 102 which drives the rear wheel 101. Further, the electric motor 102 has two parts: a rotating member called a rotor 102R houses multiple permanent magnets mounted inside it and a stationary member called a stator 102S contains stationary copper windings connected to the battery module 104 through the control units 106. Further, the stator 102S of the traction motor 102 includes threaded portions 201L and 201R at both the ends. The threaded portion 201L receives a left handed nut 202L on one end and the threaded portion 201R receives a right handed nut 202R on another end. Thus, both the nuts 202L and 202R are assembled in opposite direction on both shaft ends, thereby not allowing the shaft to rotate in either clockwise or anti-clockwise directions.

[00026] Fig. 3 exemplarily illustrates the first holding provision 301 at the first holding location 302 of the vehicle 101. The terminal cable 103 exiting from the motor shaft is arrested at the first holding location 302 on the swing arm portion 105a using the first holding provision 301. The first holding provision 301 is a bracket with an annulus 301a that allows the clamper 600 exemplarily illustrated in Figs. 6A-6B to engage with the bracket. The bracket is removably attached to the swing arm portion 105a at the holding location 302 by means of one or more fasteners. In an embodiment, the bracket may be permanently welded to the swing arm portion 105a at the holding location 302. The clamper 600, in an embodiment, is a button clip exemplarily illustrated in Figs. 6A-6B. The button clip prevents the terminal cable 103 to rub against the swing arm portion 105a and hold it in place in a stable manner and hence avoid direct stress at the motor wire-out. As exemplarily illustrated in Fig. 3, the first holding location 302 is proximal to one of the distal ends of the swing arm portion 105a. In an embodiment, the first holding location 302 may be centrally located on the swing arm portion 105a. The purpose of arresting the terminal cable 103 on the swing arm portion 105a avoids rubbing of the terminal cable 103 against the swing arm portion 105a both during static as well as dynamic movements, thereby preventing damage to the terminal cable 103.

[00027] Fig. 4 exemplarily illustrates the second holding provision 401 at the second holding location 402 of the vehicle 100. The second holding provision 401 is a bracket located at the second holding location 402. The second holding provision 401 may be extending from a side wall of the storage frame 107 of the battery module 104. In an embodiment, the second holding provision 401 may be a fixture removably attached or permanently welded to the storage frame 107 of the battery module 104. The second holding location 402 is on the side wall of the storage frame 107 of the battery module 104. In another embodiment, the second holding location 402 may be located on top or bottom of the storage frame 107. That is, the second holding location 402 of the second holding provision 401 on the storage frame 107 is located on a front surface, a rear surface, or a side surface of the storage frame 107 for securing the terminal cable 103. The terminal cable 103 is taken under the utility box area 110 exemplarily illustrated in Fig. 1 and is secured at the second holding location 402. The second holding provision 401 is a bracket with an annulus 401a where the clamper 600 engages with the terminal cable. The clamper 600 is removably inserted into the annulus 401a of the second holding provision 401. The terminal cable 103 when arrested in the second holding location 402 using the clamper 600 avoids stress from the side panels and clipping of the terminal cable 103 from sharp edges of the frame 109 of the vehicle 100. Also, the risk of shorting between the terminal wires in the terminal cable 103 or ground short circuit is avoided in the vicinity of the battery module 104 in the storage frame 107.

[00028] Fig. 5 exemplarily illustrates the third holding provision 501 at the third holding location 502 of the vehicle 100. The third holding provision 501 is a bracket extending from the storage frame 108 of the control units 106 at the third holding location 502. The third holding location 502 is on the side wall of the storage frame 108. In an embodiment, the third holding location 502 may be located on top or bottom of the storage frame 108. That is, the third holding location 502 of the third holding provision 501 on the storage frame 108 is located on a front surface, a rear surface, or a side surface of the storage frame 108 for securing the terminal cable 103. In an embodiment, the third holding provision 501 may be a fixture removably attached or permanently welded to the storage frame 108 of the control units 106. The last holding location of the terminal cable is the third holding location 502 on the storage frame 108 of the control units 106. The terminal cable 103 terminates at the control units 106 in the storage frame 108. At the third holding provision 501, stress on the terminal cable 103 when a rider sits or open the utility box or when any other kind of action which leads to seat movement, is avoided.

[00029] The third holding provision 501 has annuli 501a and 501b at the ends that allow the clamper 111 to engage with the bracket. The clamper engages with one of the annuli 501a or 501b based on the control unit in the storage frame 108 at which the terminal cable connects. In an embodiment, if the terminal cable 103 connects to the left most control unit, the terminal cable 103 is secured to the third holding provision 501 at the annulus 501a. In accordance to an embodiment of the invention, if the terminal cable 103 connects to the right most control unit, the terminal cable 103 is secured to the third holding provision 501 at the annulus 501b. The clamper is removably inserted into either of the annuli 501a and 501b of the third holding provision 501. Such restrictions in the position and routing of the terminal cable 103 using the cable routing structure 111 allows concerned party of the vehicle to control the length of the terminal cable and hence reduce the stress and avoid damage to the terminal cable in specific areas, such as, 302, 402, and 502.

[00030] Figs. 6A-6B exemplarily illustrate a clamper 600 for holding the terminal cable 103 at the first holding location 302, the second holding location 402, and the third holding location 502 of the vehicle 100. As exemplarily illustrated, the clamper 600 comprises an extension member 601, a strap 602 extending from the extension member 601, and a locking member 603 extending from the strap 602. The extension member 601 removably engages with each of the holding provisions, such as, 301, 401, and 501. The extension member 601 enters or exits from the annuli 301a, 401a, 501a or 501b of the holding provisions such as, 301, 401, and 501. The clamper 600 further includes a retainer 604 that flushes against the circumference of the annuli 301a, 401a, 501a or 501b to prevent exertion of stress on the extension member 601. The extension member 601 is inserted into the annuli 301a, 401a, 501a or 501b until the retainer 604 comes in contact with the surface of the annuli 301a, 401a, 501a or 501b. Another distal end of the extension member 601 comprises of claw-like members 605 that are flexible and lock the extension member 601 in the annuli 301a, 401a, 501a or 501b. To remove the extension member 601 from the annuli 301a, 401a, 501a or 501b, external force to fold the claw-like members 605 needs to be applied and then the extension members 601 needs to be pulled out. The claw-like members 605 allow locking of the extension member 601 in the annuli 301a, 401a, 501a or 501b. In an embodiment, the retainer 604 is conical in shape. The retainer 604 contributes to increasing the durability of the clamper 600 by preventing damage to the extension member 601 due to stress experienced by the terminal cable 103.

[00031] From the retainer 604, the strap 602 extends on both sides of the extension member 601 and accommodates the terminal cable 103. The flexible strap 602 takes different profiles, such as a partial circle, a partial rectangle, a partial trapezoid, etc., to accommodate the terminal cable 103. The overall shape of the clampers 600, that is, the encompassing profile of the clampers 600 is a substantial circle, a substantial rectangle, a substantial triangle, a substantial trapezoid, a substantial square, etc. The material of the clampers 600 can be resin, plastic, nylon, or metal. The strap has two ends 602a and 602b. A slit 606 is formed in the strap 602 by means of a flap member 607 extending peripherally outwards from the strap 602. The slit 606 is wider at the point of contact with the strap 602 and narrows towards the end 602a of the strap 602. The locking member 603 extends sideways proximal from the end 602b of the strap 602 and removably engages in the slit 606 at the end 602a of the strap 602. The locking member 603 may be pulled back or opened after lifting the flap member 607 in the slit 606 and opened. The locking member 603 along with the strap 602 forms a pull-back lock that forms a tight loop to hold the terminal cable 103 at the holding location, such as, 302, 402, and 502. The pull-back lock provides ease of assembly and serviceability of the terminal cable 103.

[00032] Using such clampers 600 for arresting the terminal cable 103 in holding locations, such as, 302, 402, and 502, fixes the position of the clamper 600 to be mounted in the vehicle 100 that does not change while assembling or servicing, hence routing is always done in a stable, adaptable, and secure manner. There exists operable gap between the locking member 603 and the strap end 602a which increases or reduces based on engagement of the teeth on the flap member 607 with teeth on the locking member 603 thereby providing adaptable dimension of the cable or harness clamping circumferentially clamped within the inner periphery of strap 602. The cable routing structure 111 exemplarily illustrated in Fig. 1 adds support to the dangling terminal cable 103 to avoid stress at the start and the end point of the terminal cable 103, thereby reducing the chances of the terminal cable 103 from getting damaged. The cable routing structure 111 supports the terminal cable 103 at a lower portion of the vehicle100 and prevents water entry and fire accidents caused by the water entry and stalling of the vehicle 100, thereby ensuring smooth functioning of the vehicle 100.