EP4225631A1

EP4225631A1 - A saddle-type vehicle

Info

Publication number: EP4225631A1
Application number: EP20842737.7A
Authority: EP
Inventors: Vishwanath Patil LOHIT; Ramakrishna Naraharisetti; Sridhar Balaguru; Anu Karthick NARAYANA REDDY
Original assignee: TVS Motor Co Ltd
Current assignee: TVS Motor Co Ltd
Priority date: 2020-10-10
Filing date: 2020-12-30
Publication date: 2023-08-16
Also published as: WO2022074665A1

Abstract

The present subject matter relates generally to a controller 111 for a saddle-type vehicle 100. The frame 101 having a head tube 102, a front frame region (F), and a rear frame region (R). The front frame region (F) extends rearwards from the head tube 102. A controller 111 disposed on at least a portion of said front frame region(F). The mounting mechanism provides a secure, precise and robust location for the controller 111 which is compact, reduces energy losses, maintains centre of gravity, ensures efficient cooling, improves assembly and serviceability.

Description

A Saddle-type vehicle

TECHNICAL FIELD

[0001] The present subject matter relates generally to a vehicle, and more particularly but not exclusively relates to a controller of the vehicle.

BACKGROUND

[0002] Generally, the major components of an electric vehicle or hybrid vehicle system include a motor, a controller, a power source, a charger, and a drive train. The controller is the brain of the electric vehicle. The controller is employed to regulate the torque generated by the motor of the electric vehicle by controlling the flow of energy from the power source to the motor. The controller calculates the amount of energy needed by the vehicle to go smoothly on the road, based on the inputs received from the rider of the vehicle. The controller is connected to the power source and the motor through a wiring harness required for transmitting the power from the power source to the motor. With an increasing demand of the compact vehicles with high functionality, particularly for compact electric and hybrid vehicle, the packaging layout of the vehicles is extensively explored and been worked upon to provide maximum vehicle performance and also to safeguard from any type of accidents.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The details are described with reference to an embodiment of a two-wheeled electric vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components.

[0004] Figure 1(a) exemplarily illustrates a perspective right side view of a twowheeled electric vehicle.

[0005] Figure 1(b) exemplarily illustrates a perspective left side view of a twowheeled electric vehicle.

[0006] Figure 2 (a) exemplarily illustrates a perspective front view of the mounting means of the controller on the frame of the vehicle. [0007] Figure 2(b) exemplarily illustrates a perspective rear view of the mounting means of the controller on the frame of the vehicle.

[0008] Figure 3 exemplarily illustrates a magnified local side view of the controller along with the wiring harness, mounted on the frame of the vehicle.

DETAILED DESCRIPTION

[0001] With the developments of new features in an electric or hybrid vehicle, new parts or components are introduced, and it is often required to accommodate all parts in a conventional layout. In electric vehicles and hybrid electric vehicle, a controller is located away from a power source and a motor. This results in energy losses and reduces the efficiency of the vehicle, and also increases the length of the wiring harness which is undesirable. Additionally, to maintain the driving efficiency and achieve good dynamic handling performance of the vehicle, a means for cooling the controller is to be provided within a compact space. Apart from this, the center of gravity of the vehicle is to be maintained low, while packaging the heavy components like the motor, a battery, the controller, and the like to enable good maneuverability and agility of the vehicle as well as stability cum safety at various riding speeds. Therefore, there exists a need for a solution for packaging the controller and other parts, which meets above challenges and overcomes limitations and compromises of known art.

[0002] Mounting layout for the controller in any vehicle is very critical, and should be located such that the distance of the controller from the motor and the battery does not affect the efficiency of the vehicle. An objective of the present subject matter is to provide a secure, precise and robust location for the controller which is compact, reduces energy losses, maintains center of gravity, ensures efficient cooling, improves handling performance, ease of assembly as well as serviceability. The present subject matter is described using an exemplary two-wheeled electric vehicle, whereas the claimed subject matter is also applicable to a two-wheeled hybrid electric vehicle, with required changes and without deviating from the scope of invention. In the present subject matter, a saddle-type vehicle includes a frame having a head tube, a front frame region and a rear frame region. The front frame region extends rearwards from the head tube. A controller disposed on at least a portion of said front frame region.

[0003] As per an aspect of the present subject matter, the front frame region includes a front portion and a rear portion. The front portion extends rearwards from said head tube, and the rear portion extends rearwards and downwards from said front portion. The controller being disposed on at least a portion of said rear portion. [0004] As per an aspect of the present subject matter, the controller being disposed above a battery housing and mounted on at least one of a left-side frame member and a right-side frame member of the rear portion.

[0005] As per an aspect of the present subject matter, the controller is attached to the right-side frame member of the rear portion.

[0006] As per an aspect of the present subject matter, the controller being configured to be disposed substantially below a joining region. The joining region joins the front portion to the rear portion of the frame structure.

[0007] As per an aspect of the present subject matter, the joining region being defined by an area below a rider seating having the frame structure with one or more portions extending substantially downwardly towards the ground.

[0008] As per an aspect of the present subject matter, the controller is mounted on a cross bracket connecting the right-side frame member and the left-side frame member of the rear portion.

[0009] As per an aspect of the present subject matter, the controller is mounted on one of the right-side frame members and the left-side frame members through a plurality of affixing means e.g. bolts. The affixing means are made of metal and are configured to transfer heat from said controller to the one of the right-side frame member and the left-side frame member.

[00010] As per an aspect of the present subject matter, the battery housing width being substantially equal to the width of a footstep space of the vehicle.

[00011] As per an aspect of the present subject matter, a wiring harness from said controller is connected to a battery connector on a front frame region, and to a motor in a rear frame region of the vehicle. [00012] As per another aspect of the present subject matter, the controller includes a holding bracket configured to guide and support said wiring harness.

[00013] As per another aspect of the present subject matter, a vehicle comprises of a controller, a battery housing, and a motor. The motor being encompassed by an imaginary circle having a radius, when viewed from the side view of the vehicle. The motor partially overlaps the controller and the battery housing.

[00014] As per another aspect of the present subject matter, a cumulative height of the controller encompassing cuboid plus a battery housing height being more than twice the motor encompassing radius.

[00015] As per another aspect of the present subject matter, the controller being configured to be positioned above the battery housing in a side view of the vehicle, and a length of the controller at least partially overlaps a length of the battery housing in a side view of the vehicle.

[00016] As per another aspect of the present subject matter, the motor configured to be mounted in a swingable manner laterally co-axial with a transmission unit. The motor is disposed substantially rearward of the controller.

[00017] As per another aspect of the present subject matter, a drive axis of the motor being disposed above an imaginary line joining an axis of a front wheel and a rear wheel.

[00018] As per another aspect of the present subject matter, the outer circumference of the motor being determined by the motor body encompassing radius substantially overlaps the imaginary line. The motor simultaneously overlaps at least a portion of the controller and the battery housing when seen in a side view of the vehicle. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof. [00019] Fig. 1(a) exemplarily illustrates a perspective right side view of a twowheeled electric vehicle 100 wherein the seat and side and other panels are omitted for clarity. Fig. 1(b) exemplarily illustrates a perspective left side view of a twowheeled electric vehicle 100. Said two-wheeled electric vehicle 100 includes a front frame region (F), a rear frame region (R), a frame 101, a front wheel 105, a front suspension unit 106, a rear wheel 107, a rear shock absorber 108, a transmission unit 109 (shown in fig 1(b)), a controller 111, a battery housing 112, a motor 113, and a battery connector 114.

[00020] The frame 101 includes a head tube 102, a front portion 101(a), a rear portion 101(b), a left-side frame member 104(a) (shown in fig 1(b)), and a rightside frame member 104(b). The front portion 101(a) of the frame 101 extends rearwards from the head tube 102 and the rear portion 101(b) extends rearward and downwards from said front portion 101(a). The front portion 101(a) and the rear portion 101(b) includes a left-side frame member 104(a) (shown in fig 1(b)) and a right-side frame member 104(b) running parallelly rearward and then downward till the battery housing 112 of the vehicle 100. The front suspension unit 106 is supported by the head tube 102 at the upper end and lower end is supported by the front wheel 105 in front frame region (F). The rear shock absorber 108 is inclinedly disposed in the rear frame region (R) of the vehicle 100. The upper end of the rear shock absorber 108 is supported by the rear portion 101(b) of the frame 101, and the lower end of the rear shock absorber 108 is supported by an axle of the rear wheel 107, placed in the rear frame region (R) of the vehicle 100. The transmission unit 109 (shown in fig 1(b)) is disposed in the rear frame region (R) of the vehicle 100, and is supported by the rear wheel 107 at one end and by the frame 101 at the other end. The vehicle 100 includes the battery housing 112, disposed below the front portion 101(a) of the frame 101 and extends horizontally rearward in vehicle longitudinal direction, till it reaches to connect with the rear portion 101(b) of the frame 101.

[00021] In the present embodiment, a battery (not shown) is placed inside the battery housing 112 and said housing 112 acts as a floorboard of the vehicle 100. The motor 113 is placed in the rear frame region (R), disposed behind the rear portion 101(b) of the frame 101. The controller 111 of the vehicle 100 is disposed between the left-side frame member 104(a) (shown in fig 1(b)) and the right-side frame member 104(b) such that it is substantially below the joining region (J) which joins the front portion 101(a) to the rear portion 101(b) of the frame structure 101. In the present embodiment, the controller 111 is mounted on the right-side frame member 104(b). However, the controller 111 can be disposed anywhere between the left-side 104(a) (shown in fig 1(b)) and the right-side frame member 104(b). In another embodiment, the controller 111 is mounted on a cross bridge member 104(c) (shown in Fig 2(b)) disposed between the left side frame member 104(a) (shown in fig 1(b)) and the right-side frame member 104(b). In alternate embodiments, the controller 111 can be disposed on any type of frame, such as sheet metal frames, tubular frames, and the like and configured to be disposed substantially below the region (J) wherein region (J) is defined by attachment of the front portion 101(a) of the frame 101 is attached to the rear portion 101(b) of the frame 101. Alternatively, region (J) is defined by the area below a rider seating (not shown) where the frame structure has one or more portions extending substantially downwardly towards the ground.

[00022] The configuration of the controller 111 at this location facilitates in increase of efficiency and reduces the losses of the vehicle 100 by minimising wiring harness length and its transmission losses. The controller 111 is disposed and packaged such that the controller 100 is near and in close vicinity to the battery (not shown) as well as the motor 113. This placement also reduces length of wiring harness 118 (shown in Fig 3) from the motor 113 to the controller 111 to give maximum efficiency and to reduce the losses of the vehicle 100. The reduction in wiring harness 118 reduces the cost of the wire, facilitates ease of routing during assembly and serviceability of the vehicle 100. The controller 111 is disposed in the lower portion of the vehicle 100 which balances the centre of gravity of the vehicle 100. The center of gravity of the vehicle 100 as per the present invention is achieved to be substantially close to the lateral centre of the vehicle 100, and lower in vertical direction from ground resulting in significant enhancement of handling dynamics of the vehicle 100. To balance the centre of gravity, the controller 111 is placed as illustrated in the illustration shown in fig. 1(a) and (b).

[00023] Fig. 2(a) exemplarily illustrates a perspective front view of the mounting means of the controller 111 on the frame 101 of the vehicle 100. Fig. 2(b) exemplarily illustrates a perspective rear view of the mounting means of the controller 111 on the frame 101 of the vehicle 100. In the present embodiment, the controller 111 is mounted on the right-side frame member 104(b) by means of a plurality of affixing means e.g. bolts 115. In the present embodiment, the controller 111 is mounted using three-point mounting. Two mountings 116 are provided on the upper portion of the right-side frame member 104(b) and one mounting 117 is provided at the lower portion of the right-side frame member 104(b). However, the number of mounting points can be increased and decreased to suit the requirements of the vehicle 100. The mounting points, apart from mounting the controller 111, also facilitates in cooling of the controller 111. The mounting points conducts the heat from the controller 111 to the frame 101 and thus the heat is given away to the atmosphere, by way of conduction. So, the contact between the controller 111 and the frame 101 of the vehicle 100 is achieved by the mounting points to transfer the heat generated in the controller 111 by natural cooling, without using any extra component. Apart from this, the placement of the controller 111 on the right-side frame member 104(b), creates additional adjacent space which can be utilized for disposing auxiliary battery (not shown), or the space can be used as storage depending upon the vehicle layout and requirements. The controller 111 has a predetermined size defined by volume encompassed imaginary cuboid of width (CW), height (CH), and length (CL).

[00024] Fig. 3 exemplarily illustrates a side view of the layout configuration of the vehicle 100 as per the present invention and a magnified local side view of the controller 111 along with the wiring harness 118, mounted on the frame 101 of the vehicle 100. The controller 111 is disposed near the battery (not shown) as well as the motor 113 of the vehicle 100. The battery (not shown) is placed in the battery housing 112 and the battery housing 112 acts as a floorboard of the vehicle 100. The battery housing 112 has a predetermined length (BHL) and a predetermined height (BHH). As per an embodiment, the battery housing 112 width is substantially equal to the width of a footstep space (not shown) of the vehicle 100. The battery connector 114 connects the battery (not shown) and the controller 111 using the wiring harness 118. The battery connector 114 is disposed above the battery housing 112, in the front frame region (F) of the vehicle 100. The layout of the vehicle controller 111, battery housing 112 and the motor 113 is configured such that an imaginary circle encompassing the motor 113 in a side view defined by radius (Mr) at least partially overlaps both the controller 111 as well as the battery housing 112 in a side view of the vehicle 100. As per another aspect of the present invention, the cumulative height of the controller 111 encompassing cuboid (CH) plus the battery housing height (BHH) is more than twice the motor encompassing radius (Mr), CH + BBH > 2 x Mr. As per an aspect of the present invention, the controller 111 is configured such that it is positioned above the battery housing 112 in a side view of the vehicle 100 and the length of the controller (CL) (shown in fig. 2(b)) at least partially overlaps the length of the battery housing (BHL) in a side view of the vehicle 100. The disposition of the controller 111 as per the present invention and the battery connector 114 facilitates ease of assembly of the wiring harness 118 and prevents any twisting or bending. The motor 113 is disposed in the rear frame region (R) of the vehicle 100 and behind the rear portion 101(b) (shown in fig 1(b)) of the frame 101. The wiring harness 118 from the motor 113 to the controller 111 is guided by a holding bracket 119 to guide and support the wiring harness 118. The holding bracket 119 restricts undesirable movement of the wiring harness 118 and avoids short circuiting due to the contact of the cables, at the motor 113 side. As per an aspect of the present invention, the motor 113 is mounted in a swingable manner laterally co-axial with the transmission unit 109 such that the motor 113 is disposed substantially rearward of the controller 111. As per an aspect of the present layout the drive axis (Mx) of the motor 113 is disposed above an imaginary line (FR) joining the axis of the front wheel (Fwx) (shown in fig 1(a)) and the rear wheel (Rwx) (shown in fig 1(a)). As per an aspect of the present invention the motor 113 is disposed such that its outer circumference determined by motor body encompassing radius (Mr) substantially overlaps the imaginary line (FR) as well as the motor 113 simultaneously overlaps at least a portion of the controller 111 and the battery housing 112 when seen in a side view of the vehicle layout. Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.

List of Reference numerals:

100: Two-wheeled electric vehicle

F: Front frame region of 100

R: Rear frame region of 100

101: Frame of 100

101 (a): front portion of 101

101 (b) : Rear portion of 101

102: Head tube

104 (a): Left-side frame member of 101(a)

104 (b): Right-side frame member of 101(a)

105: Front wheel of 100

106: Front suspension unit of 100

107: Rear wheel of 100

108: Rear shock absorber of 100

109: Transmission unit of 100

111: Controller of 100

112: Battery housing of battery

113: Motor of 100

114: Battery connector of battery

115: Affixing means of 111

116: Two mountings of 111

117: One mounting of 111

118: Wiring harness between 111 and 113

119: Holding bracket between 111 and 114

FR: Imaginary line

Claims

We claim:

1. A saddle-type vehicle (100) comprising: a frame (101) having a head tube (102), a front frame region (F) and a rear frame region (R); the front frame region (F) extends rearwards from the head tube (102); a controller (111) disposed on at least a portion of said front frame region (F).

2. The saddle-type vehicle (100) as claimed in claim 1, wherein the front frame region (F) includes a front portion (101(a)) and a rear portion (101(b)), the front portion (101(a)) extends rearwards from said head tube (102), and the rear portion (101(b)) extends rearwards and downwards from said front portion (101(a)), the controller (111) being disposed at least a portion of said rear portion (101(b)).

3. The saddle-type vehicle (100) as claimed in claim 1, wherein the controller (111) being disposed above a battery housing (112) and mounted on at least one of a left-side frame member (104(a)) and a right-side frame member (104(b)) of the rear portion (101(b)).

4. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller (111) is attached to the right-side frame member (104(b)) of the rear portion (101(b)).

5. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller (111) being configured to be disposed substantially below a joining region (J), said joining region (J) joins the front portion (101(a)) to the rear portion (101(b)) of the frame structure (101).

6. The saddle-type vehicle (100) as claimed in claim 1, wherein said joining region (J) being defined by an area below a rider seating (not shown) having the frame (100) structure with one or more portions extending substantially downwardly towards the ground.

7. The saddle-type vehicle (100) as claimed in claim 1, wherein said controller (111) is mounted on a cross bracket (104(c)) connecting the right-side frame member (104(b)) and the left-side frame member (104(a)) of the rear portion (101(b)).

8. The vehicle (100) as claimed in claim 1, wherein said controller (111) being mounted on one of the right-side frame member (104(b)) and the left-side frame member (104(a)) through a plurality of affixing means (115), said affixing means (115) are made of metal and are configured to transfer heat from said controller (111) to the one of the right-side frame member (104(b)) and the left-side frame member (104(a)).

9. The vehicle (100) as claimed in claim 1, wherein said battery housing (112) width being substantially equal to the width of a footstep space (not shown) of the vehicle (100).

10. The vehicle (100) as claimed in claim 1, wherein a wiring harness (118) from said controller (111) is connected to a battery connector (114) on a front frame region (F), and to a motor (113) in a rear frame region (R) of the vehicle (100).

11. The vehicle (100) as claimed in claim 10, wherein said controller (111) includes a holding bracket (119) configured to guide and support said wiring harness (118).

12. A vehicle (100) comprising: a controller (100); a battery housing (112); and a motor (113), said motor (113) being encompassed by an imaginary circle having a radius (Mr), when viewed from the side view of the vehicle (100); wherein said motor partially overlaps the controller (111) and the battery housing (112).

13. The vehicle (100) as claimed in claim 12, wherein a cumulative height of the controller (111) encompassing cuboid (CH) plus a battery housing height (BHH) being more than twice the motor encompassing radius (Mr).

14. The vehicle (100) as claimed in claim 12, wherein said controller (111) being configured to be positioned above the battery housing (112) in a side view of the vehicle (100) and a length of the controller (CL) at least partially overlaps a length of the battery housing (BHL) in a side view of the vehicle (100). The vehicle (100) as claimed in claim 12, wherein said motor (113) configured to be mounted in a swingable manner laterally co-axial with a transmission unit (109), said motor (113) is disposed substantially rearward of the controller (111). The vehicle (100) as claimed in claim 12, wherein a drive axis (not shown) of the motor (113) being disposed above an imaginary line (FR) joining an axis of a front wheel (Fwx) and a rear wheel (Rwx). The vehicle (100) as claimed in claim 12, wherein the outer circumference of said motor (113) being determined by the motor body encompassing radius (Mr) substantially overlaps the imaginary line (FR), said motor (113) simultaneously overlaps at least a portion of the controller (111) and the battery housing (112) when seen in a side view of the vehicle (100).