TECHNICAL FIELD

[0001] The present subject matter relates to a saddle type vehicle. More particularly, the present subject matter relates to a cooling system for cooling of electrical component in the saddle type two and three wheeled vehicle.

BACKGROUND

[0002] Conventionally, most of vehicles are propelled by an internal combustion engine which uses fossil fuels as a source of energy. The gases formed by combustion of the fossil fuels within the internal combustion engine are exhausted from such vehicles to the atmosphere, which leads to increased air pollution in the atmosphere.

[0003] Presently, in view of the same, electric vehicles are used as a substitute for the vehicles using fossil fuels. However, such vehicles are required to be equipped with energy storage units having a large capacity in order to propel the vehicles through large distances. So, the vehicles typically include one or more battery, a motor and drive train supported on a frame and enclosed in a body, which propels the vehicle through large distances. Further, the electric vehicles (EVs) are currently experiencing increasing demand due to the growing price of fossil fuels and undesirable emissions from traditional internal combustion engine vehicles. Hybrid power trains are also being implemented as a substitute to maximise distance travel and reduce emissions.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The detailed description is described with reference to an embodiment of a two wheeled saddle type vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.

[0005] Fig.l is a side view of a saddle type vehicle as per one embodiment of the present invention.

[0006] Fig.la is a perspective view of a frame of saddle type vehicle as per one embodiment of the present invention. [0007] Fig. lb is an assembled view of a cooling system as per one embodiment of the present invention.

[0008] Fig.2 is a front view of a saddle type vehicle as per one embodiment of the present invention.

[0009] Fig. 2a is a side view of a saddle type vehicle with atmospheric air as per one embodiment of the present invention.

[00010] Fig. 3 is an exploded view of the cooling system as per one embodiment of the present invention.

[00011] Fig. 3a is a left side view of the cooling system as per one embodiment of the present invention.

[00012] Fig. 4 is block diagram of the cooling system as per one embodiment of the present invention.

[00013] Fig. 5 is flow chart as per one embodiment of the present invention.

DETAILED DESCRIPTION

[00014] The arena of technology pertaining to transportation has undergone a tremendous transformation over the years, such that the present concentration is focused upon the efficiency and cost of manufacturing, which includes the cost of materials, assembly cost, cost of inventory handling etc. Simultaneously, there has also been a need in the industry to provide stronger, lighter and economically advantageous vehicles that consume less power. Electric power storage device driven vehicles happen to be eco- friendly, in line with the Go Green initiative of various organizations. These vehicles may be two, three or four wheelers depending upon the requirement of the consumer and have multiple applications.

[00015] In automobile vehicle industry, electric vehicles are introduced to control air pollution caused due to IC engine powered vehicles. Currently, the electric vehicles are classified into two groups, namely pure electric and extended electric vehicles (also known as hybrid vehicles). The hybrid vehicles have a primary electric drive with associated energy storage device and an internal combustion engine coupled to an electric motor/generator. [00016] In recent years, the electric vehicles have become quite popular due to high oil prices and the environmental impact of pure gasoline fuel consumption vehicles. The electric vehicles using an electric motor as a driving source and hybrid vehicles combining other driving sources such as the electric motor and the engine have been put to practical use. The above-mentioned automobile is equipped with an electrical component like an energy storage device, for supplying electric power as electric energy to an electric motor. In this particular type of vehicles, the vehicle's driving force is provided from the energy storage device in order to receive the energy required for driving the vehicle. The energy storage device, for example, a battery that can be repeatedly charged and discharged, such as a nickel-cadmium battery, a nickel-hydrogen battery, and a lithium-ion battery, is used.

[00017] The electrical components like the electric motor, the energy storage unit have been used in transportation applications, such as in automobiles. The electrical component like the electric motor generates substantial amount of heat during operation. The electric motor needs to be cooled in order to continue prolonged duration running, avoid undesirable damage as well as to ensure smooth and efficient operation of the motor. As, transportation applications need to be compact especially saddle type vehicles which do not have layout luxury of space unlike a four wheeler, manufacturers prefer to put a premium motor of smaller size and lower weight, since these motors are more power dense and therefore are also more difficult to cool. As the size of the motor is decreased, the amount of heat to be dissipated becomes increasingly high as a result conventional cooling systems are often insufficient to maintain temperature of the motor at acceptable levels. Furthermore, because the motor is now often on transportation vehicles, they are subject to a variety of temperature ranges and environments. Hence, there is a need of improved cooling system for the electric motor to maintain the electric motor in desirable temperature for efficient operation.

[00018] In this regard, in known art, multiple ways have been disclosed for cooling of the electrical component like electric motor. One of the ways is to use a fan for continuous cooling of the electric motor. This configuration has its own disadvantage. The fan being power driven by the energy storage unit, its continuous operation undesirably increases load on the energy storage unit resulting in drop of efficiency of power generation. Thus, at long run of the vehicle, this impacts the efficiency of the electric motor, hence decreasing the overall performance of the vehicle.

[00019] In another known art, a cooling system with refrigerant is disclosed. The refrigerant is channelized inside the electrical component like the motor through output shaft of the motor. The refrigerant after being used for cooling is channelized to a motor case and collected inside the case for circulation. However, this system has its own disadvantage that, in case of motor having magnets, the refrigerant is brought into the contact of the magnets. Since the magnets have a lower heat resistance than the other constituent members, there have been problems that the magnets deteriorate by coming into contact with the refrigerant which has a high temperature leading to inefficient cooling system.

[00020] In another known art, a cooling system with natural air cooling is disclosed. This configuration has its own disadvantages as the size of the electrical component like motor is decreased, air cooling alone is not always sufficient to maintain the optimum temperature of the electrical components like the electric motor especially when vehicle is to be driven at higher speeds or for long duration or with higher payload. Furthermore, in a scenario, when the vehicle is at region having high temperature, the natural air at that region may not able to cool the component as required to maintain the desired temperature of the component.

[00021] Therefore, there is a need to have an improved cooling system which overcomes all of the above problems and other problems related known in the art.

[00022] The present invention provides a solution to the above problem while meeting the requirements of minimum modification in the vehicle yet enabling design a compact vehicle layout.

[00023] With the above objectives in view, the present invention is an improved cooling system configured with an air circulating unit and an air channelizing unit working synergistically, to provide both natural and electrically driven cooling to the electrical component while maintaining efficient performance of the vehicle.

[00024] As per one aspect of the present invention, a frame assembly for a vehicle comprising a head tube, a main frame, a pair of seat rails extended rearwardly from the main frame. An energy storage unit is disposed at front end of a floorboard in the vehicle. A holding member is extended vertically and disposed forwardly on the floorboard. The energy storage device is securely disposed with the holding member on the floorboard of the vehicle. An electrical component like an electric motor is disposed rearwardly with respect to the energy storage unit. A transmission assembly is detachably attached to the electrical component like the electric motor, where the transmission assembly and the electric motor are combinedly termed as ‘power train assembly’. In another implementation, the electrical component may be a controller, an energy storage unit etc.

[00025] As per one aspect of the present invention, an air channelizing unit is disposed forwardly in the vehicle and extended rearward and downwardly, where the air channelizing unit is connected to a casing assembly of the electrical component like electric motor. The air channelizing unit is housed in a top portion of the holding member. The air channelizing unit is detachably attached to the main frame with various attachment means like a mounting bracket. The air channelizing unit includes at least an inlet and an outlet portion. The inlet of the air channelizing unit is disposed between the front fender and a front panel in upward and downward direction and between the pair of front suspension of the vehicle from sides, when the vehicle is viewed from front view. As per one aspect of the present invention, the outlet of the air channelizing unit is detachably attached in the proximity of the electrical component like the electric motor, ensuring channelizing of atmospheric air to the electrical component for cooling.

[00026] As per one aspect of the present invention, the electrical component like the electric motor is disposed in the casing assembly in the vehicle. The casing assembly includes a bottom covering member, a top covering member, a pair of sealing members, an air circulating unit and an air circulating unit grill. The electric motor is attached to the transmission assembly for providing driving power to a rear wheel of the vehicle. The electric motor is covered with the bottom covering member along with the sealing member from the bottom portion. The electric motor is further covered with the top covering member along with the sealing member from the top portion of the electric motor. The top covering member and the bottom covering member with the pair of sealing member are integrally attached with each other, ensuring no loss of air while cooling. The top covering member has an opening to configure air circulating unit and air circulating unit grill for circulating air for cooling the electric motor in the vehicle. The top covering member has an opening to detachably attach the outlet of the air channelizing unit for channelizing atmospheric air to the electric motor.

[0001] In the ensuing exemplary aspects, the vehicle is a saddle type vehicle. However, it is contemplated that the concepts of the present invention may be applied to any of the two wheeled vehicles without defeating the spirit of the invention.

[0002] Various other features of the invention are described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. The drawing in which an element first appears is indicated by the leftmost digit(s) in the corresponding reference number. With reference to the accompanying drawings, wherein the same reference numerals will be used to identify the same or similar elements throughout the several views.

[0003] Further “front” and “rear”, and “left” and “right” referred to in the ensuring description of the illustrated embodiment refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the saddle type vehicle. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers to a side to side, or left to right axis relative to the vehicle. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Further, the present subject matter can also be used in any two- wheeler.

[0001] Fig. 1 is a left side view of an exemplary saddle type vehicle having a frame assembly (101) partially shown schematically by dotted lines, in accordance with an embodiment of present subject matter. A handle bar (126) is disposed over a head tube. The handle bar (126) is connected to a front wheel (129) by one or more front suspension(s) (130) (as shown in fig. la). A front fender (131) is disposed above the front wheel (129) for covering at least a portion of the front wheel (129). The vehicle (100) is provided with lighting means which includes Head lamp (not shown), Tail lamp (not shown), Turning indicators includes front side indicators (not shown) and rear side indicator (not shown) respectively. A rear fender (138) is projected outwardly of the vehicle systems to protect pillion from mud splash as well as to protect the rear wheel (133) from environmental damage. A power unit (125) (as shown in fig. la) is mounted to the lower portion of frame (101). In an embodiment, the power unit (125) is an electric motor. A transmission assembly (134) is disposed rearwardly of the vehicle and is coupled with the electric motor to provide drive power to a rear wheel (133) of the vehicle. The electric motor (125) and the transmission assembly (134) is combinedly termed as power train assembly which is pivotally attached at the downward end of the main frame (140). An axis of rotation (AA’) of the electric motor (125) is disposed rearwards of pivotal axis (CC’) of the power train assembly which is disposed at the downward end of the main frame (140) A seat (132) is extended in a longitudinal direction along seat frames (142). Further, the frame assembly (101) is covered by plurality of body panels mounted on the frame assembly (101) and covering the frame assembly (105) and parts mounted thereof. A floorboard (155) is disposed at the step-through portion, wherein the floorboard (155) is capable of carrying loads.

[0004] Fig. la is a left side view of a frame assembly (101), as per one embodiment of present subject matter. The frame assembly (101) of the vehicle (100) is provided with a head tube (139) that includes a main frame (140) extended rearward and diagonally downward from the head tube (139), a pair of seat frames (142) extended backward from the rear of the main frame (140). The main frame member (140) includes a front projecting member, that is, a floor board support member (155a) helps in supporting the floorboard (155). The floorboard support member is made up of material like steel and the floorboard member is made up of material like resin, ensuring rigid support to the floorboard as disposed in the vehicle.

[0005] A holding member (145) is extended vertically downwardly from the main frame (140) and disposed and attached at front region of the floorboard support member (155a) with various attachment means like a bracket (156) thereby forming a quadrilateral storage space (dotted line shown by vertices ABCD) between the holding member (145), the main frame member (140) and floorboard supporting member (155a). An energy storage device (147) is securely disposed in the quadrilateral space attached with the holding member

(145) and supported on the floorboard support member (155a) of the vehicle that drives the electric motor (125). As per one embodiment of the present invention, a cooling system

(146) (as show in fig. lb) includes an air channelizing unit (201) and an air circulating unit (301) for maintaining optimum temperature of the electrical component. [0002] Fig. 2 is a front view of the vehicle as per one embodiment of the present invention. As per one embodiment of the present invention, the air channelizing unit (201) is disposed forwardly in the vehicle (100). For clarity, Fig la and Fig 2 are discussed together. The air channelising unit is configured with an inlet port (201i) at the forward region of the vehicle and is design to extend rearward substantially horizontally and then bent diagonally downward substantially along the respective line BC of the quadrilateral ABCD, wherein the air channelizing unit at the downstream end is configured with an outlet port (20 lo) which is connected to a casing assembly of the electrical component like electric motor (125) in the vehicle. The air channelizing unit (201) is detachably attached to the main frame (140) (as shown in fig. lb) with various attachment means like a mounting bracket

(202). The air channelizing unit includes at least an inlet (201i) and an outlet (201o) (as shown in fig. la). As per an embodiment of the present invention, the inlet (201i) of the air channelizing unit (201) is disposed between the front fender (131) and a front panel (205) in upward and downward direction and between the pair of front suspension (130) of the vehicle from sides, when the vehicle is viewed from front view. As per one embodiment of the present invention, the outlet (201o) (as shown in fig. la) of the air channelizing unit is detachably attached in proximity of the electric motor (125) (as shown in fig. la) of the vehicle, ensuring channelizing of atmospheric air (as shown in fig. 2a) to the electrical component e.g. an electric motor (125) for cooling.

[0003] Fig. 3 is an exploded view of the cooling system as per one embodiment of the present system. The cooling system includes the air channelizing unit (201) and the air circulating unit (301). The air channelizing unit (201) includes a contoured duct member

(203) forming an upstream portion followed by an elastic member (302), which is detachably attached to a rear end (201a) of the duct member (203) with various attachment means like fastener (201b). The duct member (203) extended rearwardly and then, bent partially diagonally downward to form the rear end (201a) and the elastic member (302) is detachably attached to the rear end of the duct member (203) to form air channelizing unit (201). More precisely, the downstream portion of the elastic member (302) forms the outlet (201o) of the air channelizing unit (201) and the duct member (203) includes the inlet port (201i) of the air channelizing unit (201). A cross section (B) of the inlet port (201i) is more than a cross section (D) of the duct member (203), ensuring channelizing of atmospheric air to the casing assembly of the electrical component. A sealing member (304) is disposed between the rear end (201a) of the duct member (203) and front end (302a) of the elastic member (302), eliminating leakage of atmospheric air from the air channelizing unit (201). Further, as per one embodiment of the present invention, the electrical component like electric motor (125) is housed in the casing assembly (305). The casing assembly includes a bottom covering member (306), a top covering member (307), a pair of sealing members (308a, 308b), and an air circulating unit grill (309). The electrical component like the electric motor (125) is covered with the bottom covering member (306) attached along with the sealing member (308b) from the bottom portion. The electric motor is further covered with the top covering member (307) attached along with the sealing member (308a) from the top portion of the electric motor. The top covering member (307) and the bottom covering member (306) along with the pair of sealing member (308a, 308b) are detachably attached with each other while housing the electrical component inside it, ensuring no loss of air while channelizing the air to the electrical component. As per an aspect of the present invention, the casing assembly (305) forms a part of the powertrain assembly (not labeled). As per one embodiment of the present invention, at least a sealing member, for example, beads (310a) (as shown in fig. 3a) is disposed on an attachment area of the top covering member (307) and the bottom covering member (306) for sealing the area of attachment of top covering member (307) and bottom covering member (306), eliminating air leakage from the assembly. The top covering member includes an opening (307a), wherein the opening (307a) houses the air circulating unit (301) and the air circulating unit grill (309) for enabling circulating air for cooling the electrical component like the electric motor in the vehicle. The air circulation member grill (309) is securely housed in the opening (307a) with various means like fasteners (311), ensuring rigid attachment of the air circulating unit and air circulating unit grill with the top covering member of the casing assembly. As per an embodiment, the air circulating unit is configured to function, when the vehicle is in idle state for long period in traffic condition, or when the vehicle is in region having summer season i.e. when the electrical component is not at a desired temperature range. Further, as per one embodiment of the present invention, the top covering member (307) has an opening (307b) to detachably attached the outlet (201o ) of the air channelizing unit for channelizing atmospheric air to the electrical component like the electric motor (125). As per another embodiment, the opening (307b) is disposed either one of a left side or right side of vehicle mid plane axis (XX’)· A sealing member (303) is disposed between the opening (307b) and the outlet (201o ) of duct member (203) of the air channelizing unit (201), eliminating leakage of atmospheric air from the air channelizing unit joint with the casing assembly of the electric component. As per one embodiment of the present invention, the bottom covering member (306) of the casing assembly includes an opening (306a) for channelizing hot air outside the casing assembly, thus maintaining desired or optimum temperature of the electrical component like electric motor.

[0006] Fig, 4 is a block diagram elaborating method of cooling by cooling system as per one embodiment of the present invention. As per one embodiment of the present invention, when the vehicle is in ON state, the energy storage unit (147) provides power and activates a controller unit (401) and the electrical component like an electric motor (125) to transfer the power to transmission assembly for driving the rear wheel of the vehicle. Further, drive mode of the vehicle is provided to a controller through a drive mode sensor (402) and speed of the rotation of motor is provided by a motor speed sensor (403) in the vehicle and. When the vehicle is in running condition, the air channelizing unit channelizes atmospheric air to the electrical component like electric motor. When the vehicle is running or when the vehicle is in idle state, a sensor sends temperature of the electrical component like as the electric motor as an input to the controller unit. The controller unit (401) receives input from sensor like a motor temperature sensor (404). The controller unit (401) analyzes and compares the signals received as the inputs from the sensor with a predetermined temperature or a range of temperature stored in a lookup table of the controller unit. Further, after determining, the controller unit executes desired output that is activating the air circulating unit (301) for cooling the electrical components like the electric motor. Thus, this configuration ensures that when the natural cooling is not sufficient to cool down the electrical component like electric motor, the controller unit activates the air circulating unit, to cool down the electrical component like electric motor for maintaining desired or optimum temperature of the electrical component like electric motor. This system also ensures synergistic working of the air channelizing unit and the air circulating unit, hence decreasing load of the energy storage unit. This configuration also increases the life of the energy storage unit, thus maintaining the efficiency of the vehicle at large. [0007] Fig. 5 is a flow chart of the working of the cooling system as per one embodiment of the present invention. As per one embodiment of the present invention, a threshold limit that is a predetermined temperature (T) of the electrical component like the electric motor is stored in a lookup table of the controller unit. As per one embodiment of the present invention, in S501, when the vehicle is in ON state, it also activates components like the energy storage unit, the controller unit etc. In S 503, when the vehicle is in running condition, in S 504, the electrical component is cooled down by the air channelizing assembly. In S502, when the vehicle is in idling mode or in S 504, when the electrical components is cooled down by the air channelizing assembly, then in S 505, multiple sensors provide temperature of the electrical component as an input to the controller unit. In S 506, the controller unit analyzes the received input from the multiple sensors. In S 507, the controller determines that whether the received temperature as an input is greater than the predetermined temperature T stored in the look up table of the controller unit. In S 508, if the controller determines that the received temperature as an input is greater than the predetermined temperature T, then the controller unit activates the air circulating unit, for cooling the electrical member like electric motor, thus, maintaining desired or optimum temperature of the electrical component like electric motor. If the controller finds out that the received temperature as an input is smaller than the predetermined temperature T, the controller again receives and analyzes the raw signal sent by multiple sensors and does not actuate the air circulating unit. It is a closed loop method for continuous monitoring of the temperature of the electrical component like electric motor.

[0008] The invention helps in overcoming the problem of heating of the electrical component like electric motor.

[0009] Advantageously, the embodiments of the present invention, describes the synergistic working of the natural air channelizing unit and the forced air circulation unit thereby achieving an intelligent hybrid air cooling system for a saddle type vehicle.

[00010] Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention. List of reference symbol:

Fig. 1:

100: Saddle type Vehicle

126: Handle Bar

131: Front Fender

129: Front Wheel

130: Front Suspension

125: Power Unit

101: Frame assembly

132: Seat

138: Rear Fender

133: Rear Wheel

134: Transmission Assembly

155: Floorboard

Fig. la

139: Head Tube

140: Main frame

142: Pair of seat frames

145: Holding Member

147: Energy Storage Device

155a: Floorboard support member

156: Bracket

201 i: inlet

201 o: outlet Fig. lb

146: Cooling System 201: Air Channelizing Assembly 301: Air Circulating Assembly 201 o: Outlet

Fig. 2

205: Front Panel 203: Inlet

202: Mounting Bracket.

Fig. 3

302: Elastic Member

302a: Front end of Elastic member

201a: Rear end of air channelizing assembly.

201b: Fasteners

304: A sealing member

305: Casing Assembly

306: Bottom covering member

307: Top Covering Member

308a, 308b: a pair of sealing members

309: air circulating unit grill

310a: Sealing Member on area of attached top covering member and bottom covering member.

307a: Opening

311; Fasteners 307b: Opening 303: Sealing Member 306: Opening

Fig. 4

401: Controller Unit

404: Motor Temperature Sensor