TECHNICAL FIELD

[0001] The present subject matter relates to a saddle type vehicle. More particularly, the present subject matter relates to the mounting of housing member in a saddle type vehicle referred here as vehicle.

BACKGROUND

[0001] Conventionally, most of vehicles are propelled by an internal combustion engine which use 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.

[0002] Presently, in view of the same, electric vehicles using electrical energy as a source of power are used as a substitute for the vehicles using fossil fuels. However, such electric vehicles are required to be equipped with energy storage devices having a large capacity in order to propel the vehicles through large distances. So, the electric vehicles typically include an electric motor and drive train supported on a frame and enclosed in a body, which propel the vehicles through large distances. Energy storage units are connected to the electric motor to provide power thereto. Further, electric vehicles (EVs) are currently experiencing increasing demand due to the growing lack of fossil fuels and carbon dioxide emissions from traditional internal combustion engine vehicles. The EV fully utilizes an electric drive motor that operates from the power stored in the energy storage unit to power the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is described with reference to a passenger transport layout of a two wheeled vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.

[0004] Fig.l is a side view of a saddle type vehicle as per one embodiment of the present invention.

[0005] Fig.2 is a perspective view of a frame assembly with housing member as per one embodiment of the present invention. [0006] Fig.2a is a partial perspective view of the frame assembly with housing member as per one embodiment of the present invention.

[0007] Fig. 2b is a side view of a frame assembly with housing member as per one embodiment of the present invention.

[0008] Fig. 3 is a perspective view of a housing member as per one embodiment of the present invention

[0009] Fig. 3a is a rear view of a housing member having cooling fins as per one embodiment of the present invention

[00010] Fig. 3b is a side view of a saddle type with air flow vehicle as per one embodiment of the present invention

[00011] Fig. 4 is a perspective view of housing member assembled on the frame assembly as per one embodiment of the present invention

DETAILED DESCRIPTION

[00012] 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 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.

[00013] 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.

[00014] In recent years, electric vehicles have become quite popular due to high oil prices and the environmental impact of pure gasoline fuel consumption vehicles. Electric vehicles using electric motors as a driving source and hybrid vehicles combining other driving sources such as an electric motor and an engine have been put to practical use. The above-mentioned automobile is equipped with an electrical component like 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 an energy storage device in order to receive the energy required for driving the vehicle. As 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. The energy storage device is housed in a case and is installed in the vehicle.

[00015] Therefore, a stack of main energy storage device is typically developed while maintaining the efficiency of the energy storage device. Generally, the main energy storage device provides output of 48 volts and by a DC-DC converter, converts the high voltage into voltage required for the functioning of other electrical components like headlamp. Controller etc. The DC-DC converter converts a source of direct current (DC) from one voltage level to another and only works when the main energy storage device is awake.

[00016] Further, in certain situations, for example, during vehicle collision or accidents at night or in parked situation, some electrical components like the headlamp etc. requires minimum voltage to be in active state/ON, which leads to draining of the main energy storage device. Also, in other situation like, when the vehicle stops in midway owing to vehicle breakdown, the controller sends the command to an instrument cluster in form of an error code to alert the user about the reason for vehicle stopping. This requires the main energy storage device to be functional always, which is not possible since the main energy storage can get drained out which can potentially leave the user stranded. This also raises safety concern for the users. In this aspect, that is, to trim the load from the main energy storage device, one more type of energy storage devices has been developed namely an auxiliary energy storage device which is a low voltage energy storage device.

[00017] The main energy storage device provides energy or power to a motor of the vehicle whereas auxiliary energy storage device provides energy or power to electrical components like headlamp, hazard lamps, ECU etc. Auxiliary energy storage device has been developed to trim the load from the main energy storage device. The auxiliary energy storage device provides assistance for power supply by the main energy storage device in order to supply a voltage to electrical components such as an ECU (electronic control unit) operating with a low voltage (e.g., 12 V) and / or in order to wake up the main energy storage device.

[00018] In view of the extraordinary load upon the main energy storage device caused by the operation of the electrical components, such as controller, motor, headlamps, tail lamps, other communications equipment, auxiliary power supplies have been provided. The auxiliary power supplies, such as an auxiliary energy storage device, supplement the main energy storage device and often exclusively meet the electrical load constituted by these components. To conserve energy of the main energy storage unit, auxiliary energy storage unit etc. to the maximum extent, it is desirable to eliminate any loss of energy including transmission losses. Hence, it is desirable to have short length of wiring harness including disposition of the electrical loads, controller and motor in close proximity. From the above it is apparent that the electrical components like the main energy storage device, auxiliary energy storage device, the controller, the motor should be closely mounted such that there shall not be any voltage drop as well as any undesirable bends in the routing of the high current carrying wire while maintaining the ease of accessibility and serviceability.

[00019] Additionally, there also exists a challenge of configuring such critical electrical components in a theft proof & tamper proof manner. However, since vehicle is provided with compact layout having different essential components conventionally disposed, there exists a constraint of having sufficient space for configuring electrical components like the main storage device, auxiliary energy storage device, controller, motor etc. Therefore, there exists a challenge of achieving a compact layout of a saddle type vehicle where the electrical components like the auxiliary energy storage device, the controller and other electrical components need to be disposed in close proximity in a secure, safe manner while still being easy for assembly and service.

[00020] Generally, as per known art, a frame assembly includes a housing member, where the housing member configures to store different electrical components like, energy storage device, a motor etc. Further, the housing member is mounted to eight mounting plates present in the frame assembly, that is left and right mounting plates present at the upper portion of a main frame. A down frame has a pair of left and right mounting plates at a middle portion and a pair of left and right mounting plates at a lower portion. Further, a lower frame portion of the frame assembly has a pair of left and right mounting plates at the rear portion of the frame assembly. The electrical component like energy storage device is housed forward and upward of a motor, forming like a three side close structure. However, this configuration raises another problem like increased assembly and disassembly time. Also, increased number of mounting plates leads to increased number of welded components used to mount the housing member and also compromises with the strength of the mounting plates at the welding zone. Further, the increased number of components also leads to increased overall cost of the vehicle and also leads to increased serviceability time as the components are not easily accessible.

[00021] Hence, there exists a contradictory challenge of designing a secure housing member for electrical components for a compact two wheeled vehicle, which can ensure the safety and ease of assembly to the user having two wheeled vehicles without any major change in layout design and manufacturing set-up of the vehicle.

[00022] Therefore, there is a need to have an improved layout of the housing member, for housing electrical components like main energy storage device, auxiliary energy storage device, a controller, a motor which securely as well as safely protects the electrical components while maintaining the conventional layout of the vehicle. There is a need to have a solution for safe & secure housing member for the electrical components which is easy to access or service while overcoming all of the above problems and other problems of known art.

[00023] The present invention provides a solution to the above problems while meeting the requirements of minimum modifications in vehicle, at low cost with ease of accessibility and maintaining the stiffness of the housing member etc.

[00024] With the above objectives in view, the present invention relates to the saddle type vehicle and more particularly to the improved mounting of the housing member which securely protects the electrical components while maintaining the stiffness of the housing member.

[00025] As per one aspect of the present invention, a frame assembly comprises a head tube disposed in the front of a saddle type vehicle, a main frame extending from the head tube and extending gradually downwards towards the rear portion and takes a curve towards the bottom at the middle portion of the saddle type vehicle, commonly known as the centre frame. A down frame extends sharply downwards from the head tube, a pair of seat frames extend horizontally rearward from the middle portion of the main frame, and a pair of side tubes extending from the free end of the main frame to join the pair of seat frames at a point- located at predetermined distance from the starting of the pair of seat frames.

[00026] Further, as per one aspect of the present invention, a housing member for packaging various electrical components is mounted or detachably attached between the down frame and the centre frame with various attachments means for example, fasteners and also, acts as a stressed member of the frame assembly. The housing member is having an inclined profile towards a front side of the saddle type vehicle, which compliments with the downward profile of the down frame of the frame assembly. Further, the housing member has a mounting bracket at a front side of the housing member which conforms with the profile of a bracket present on lower end of the down frame. The housing member has mounting plate on rear side which is detachably attached with a mounting bracket present at a lower end of the centre frame of the frame assembly. This configuration ensures the stable and rigid mounting of the housing member with the frame assembly with reduced number of components.

[00027] Further, as per one aspect of the present invention, the housing member is divided into two compartments separated by a common partition plate. The first compartment has three sides where a front side has an outward extending profile with respect to the common partition plate followed by a straight profile. This profile of the front side of the first compartment of the housing member compliments with the profile of the down frame and a reinforcement member attached between the main frame and the down frame. An upper side of the housing member has rearwardly inclined profile and takes a curve towards the bottom to form a third side. The third side as formed is integrally attached to the common partition plate and also compliments with the centre frame of the frame assembly. Further, as per one aspect of the present invention, the second compartment has three sides where the front side has a depressed portion on the upper end, which forms a continuity profiles with the outward extending profile of the front side of the first compartment of the housing member. A lower end of the front side has a mounting bracket which compliments with the profile of the mounting bracket present on the lower end of the down frame of the frame assembly. A lower side of the second compartment acts as a stressed load bearing member for the housing member. A rear side of the second compartment has a mounting plate which compliments with the profile present on the lower end of the centre frame of the frame assembly with various attachment means, for example fasteners. This configuration eliminates the fouling of the housing member with other parts of the frame assembly and also, ensures the stable and secure mounting of the housing number with limited space.

[00028] Further, as per one aspect of the present invention, the first compartment of the housing member configures to stores electrical component like swappable or main energy storage device and covered or locked with a cover. The cover is provided with a locking mechanism to enable authorized access. Further, as per another aspect of the present invention, the cover of the first compartment itself has a provision to detachably attach the main energy storage device and then placing it in the first compartment of the housing member, ensuring safe and secures placement of the main energy storage device in the first compartment of the housing member.

[00029] Further, as per one aspect of the present invention, the second compartment of the housing member configure to stores various electrical components like auxiliary energy storage device, a motor, a controller, a battery management system etc. The second compartment of the housing member has various projected portions, or ribs or slots to configure to store the electrical components, for example, projected portion is provided in the second compartment to store the motor in the second compartment of the housing member. The second compartment is covered by a cover which is detachably attached to the second compartment of the housing member with various attachment means for example, fasteners. The cover has slot which conforms with the profile of the shaft present on the motor. Therefore, this configuration ensures theft proof accommodation of the electrical components in the housing member. This configuration also ensures ease of accessibility of the electrical components at the time of servicing, thereby reducing the serviceability time of the vehicle. The electrical components are closely packaged, ensuring decreased length of wiring harness, thereby reduced voltage drop and also, increases the life expectancy of the wiring harness. [00030] Further, as per one aspect of the present invention, the second compartment of the housing member bears stress as exerted by the vehicle. Hence, the second compartment of the housing member is configured with increased cross section area as compared to the first compartment of the housing member. More precisely, the section modulus of the second compartment of the housing member is more as compared to the section modulus of the first compartment of the housing member. The section modulus is defined as the strength of the given member in layman language. The bending stress of the material is inversely proportional to the section modulus. Hence, from this relation, greater the section modulus, lesser the bending stress of the housing member. Therefore, from this relation higher stiffness of the housing member is ensured while in parallel ensuring stress bearing capacity of the second compartment of the housing member.

[00031] Further, as per one aspect of the present invention, the housing member is provided with cooling fins on three sides of the housing member. As the electrical components as disposed in the housing member are in direct contact with the surface of the housing member, hence the heat dissipated by the components is transferred to the surface of the housing member. Further, atmospheric air is channelized to the cooling fins of the housing member, thereby ensuring removal of the heat as transferred on the surface of the housing member.

[00032] Further "front" and "rear", and "left" and "right" referred to in the ensuing 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 vehicle and looking forward. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers generally to a side to side, or left to right axis relative to the vehicle.

[00033] The present invention is now described briefly in connection with the rendered drawings. It should be noted that like elements are denoted by the same reference numerals throughout the description.

[00034] In the ensuing exemplary aspects, the vehicle is a saddle type electric vehicle. However, it is contemplated that the concepts of the present invention may be applied to any of the two wheeler including hybrid electric vehicles.

[00035] Fig. 1 is the left side view of an exemplary saddle type vehicle and Fig. 2 is a perspective view of a frame assembly (200), as per one embodiment of present subject matter. The vehicle (100) has a frame assembly (200), which acts as the skeleton for bearing the loads. Instrument cluster (119) is mounted on handle bar assembly (126). The handle bar assembly (126) is pivotally disposed through the head tube where it includes brake levers (not shown). The handle bar assembly (126) is connected to a front wheel (129) by one or more front suspension(s) (130). A front fender (131) is disposed above the front wheel (129) for covering at least a portion of the front wheel (129). A leg shield (not shown) is provided on the vehicle (100). The vehicle (100) has lighting means which includes Head lamp (127), Tail lamp (106), Turning indicators includes front side indicators (not shown) and rear side indicator (not shown) respectively. The rear fender (138) is projected outwardly of the vehicle systems and it protects the pillion from mud splash as well as to protect the rear wheel (133) from external components. A rear wheel hugger (not shown) is mounted on the left side of swing arm and further, a license plate, license plate illuminator and a reflex reflector mounted on the rear wheel hugger. The seat (132) extended in a longitudinal direction along the seat frames.

[00036] The frame assembly (200) of the vehicle (100) is provided with a head tube (201) that includes a main frame (202) extended backward and marginally downward from the head tube (201), a pair of seat frames (205) extended backward from the rear of the main frame (202), a down frame (203) extended substantially downward from the head tube (201), a pair of center frames (204) are extended downward from the rear of the main frame (202) . An area enclosed by the seat frames (205), the center frames (204) and the sub frames (not labeled) is substantially triangular in a side view. Further, as per one embodiment of the present invention, a housing member (134) is mounted to a lower portion of frame assembly (200). A frame reinforcement member (207) is integrally attached with the junction portion of the head pipe (201) with the down frame (203) and the main frame (202), ensuring stiffness of the frame assembly.

[00037] Further, as per one embodiment of the present invention, a housing member (134) for packaging various electrical components is mounted or detachably attached between the down frame (203) and the centre frame (204) of the frame assembly (200) with various attachments means for example, fasteners. The housing member can be detachably attached on either side of the frame assembly (200). The housing member (134) is having an inclined profile towards a front side (F) of the saddle type vehicle (100), which compliments with the downward profile of the down frame (203) of the frame assembly (200). Further, the housing member (134) has a mounting bracket (210) at front side of the housing member (134) which is detachably attached with at least a provision (208a) and hence, compliment with a profile of a mounting bracket (208) present on lower end of the down frame (203) (as shown in fig. 2a and as shown in fig. 4). This ensures of providing ease of assembly of the heavy powertrain system which is packaged inside housing member (134) to be assembled with ease and can be removed from lateral side for service.

[00038] The housing member (134) has mounting plate on rear side which compliments with a profile (209) (as shown in fig. 2b) present at a lower end of the centre frame (204) of the frame assembly (200). This configuration ensures stable and rigid mounting of the housing member with the frame assembly with reduced number of components.

[00039] Fig. 3 is a perspective view of a housing member as per one embodiment of the present invention. Further, as per one embodiment of the present invention, the housing member (134) is divided into two compartments (301, 302) separated by a common partition plate (303). The common partition plate (303) is disposed horizontally with respect to the vehicle, in middle portion of the housing member (134). The first compartment (301) has three sides (301a, 301b, 301c) where a front side (301a) has an outward extending profile (301a’) with respect to the common partition plate (303) followed by a straight profile (301a”). This profile of the front side (301a) of the first compartment (301) of the housing member (134) compliments with the profile of the down frame (203) and the reinforcement member (207) attached between the main frame (202) and the down frame (203) (as shown in fig. 2). An upper side (301b) of the housing member (134) has rearwardly inclined profile and takes a curve towards a bottom to form a third side (301c). The third side (301c) as formed is integrally attached to the common partition plate (303) and also compliments with the profile of the centre frame (204) of the frame assembly (200). Further, as per one embodiment of the present invention, the second compartment (302) has three sides (302x, 302y, 302z) where the front side (302x) has a depressed portion (302x”) on an upper end, which forms a continuity profile with the outward extending profile (301a’) of the front side (301a) of the first compartment (301) of the housing member (134). A lower end (302x’) of the front side (302x) has a mounting bracket (210) which compliments with the profile of mounting bracket (208) present on the lower end of the down frame (203) of the frame assembly (200). A lower side (302y) of the second compartment (302) acts as a stressed member for the housing member (134) to withstand loads from the systems housed inside the housing member (134) as well as other vehicular loads like road shocks, payload, vibrations etc. A rear side (302z) of the second compartment (302) has a mounting plate (307) which compliments with the profile (209) (as shown in fig. 2b) present at a lower end of the centre frame (204) of the frame assembly (200). This configuration restricts the fouling of the housing member with other parts of the frame assembly and also, ensures the stable and secure mounting of the housing number with limited space.

[00040] Further, as the second compartment (302) of the housing member (134) bears stress or load as exerted by the vehicle (100), hence, the second compartment (302) of the housing member (134) is configured with increased cross section area (304) as compared to a cross section area of the first compartment (301) of the housing member (134). More precisely, the section modulus of each side (302x, 302y, 302z) of the second compartment of the housing member is more as compared to the section modulus of each side (301a, 301b, 301c) of the first compartment of the housing member. The section modulus is defined as the strength of the given member in layman language. The bending stress of the material is inversely proportional to the section modulus. Hence, from this relation, greater the section modulus, lesser the bending stress of the housing member. Therefore, from this relation higher stiffness of the housing member is ensured while in parallel ensuring stress bearing capacity of the second compartment of the housing member.

[00041] Further, as per one embodiment of the present invention, the housing member (134) is provided with cooling fins (305) on the housing member (134). As the electrical components as disposed in the housing member (134) are in direct contact with the surface of the housing member (134), hence, heat dissipated by the components is transferred to the surface of the housing member (134). Atmospheric air is channelized to the cooling fins (305) of the housing member (134), thereby ensuring removal of the heat as transferred on the surface of the housing member (as shown on fig. 3a and 3b). [00042] Fig. 4 is a perspective view of housing member assembled on the frame assembly as per one embodiment of the present invention. Further, as per one embodiment of the present invention, the first compartment (301) of the housing member (134) configures to store electrical component like swappable or main energy storage device (404) and covered or locked with a cover (401). The cover (401) is provided with a locking mechanism to enable authorized access. Further, as per another aspect of the present invention, the cover (401) of the first compartment (301) itself has a provision to detachably attach the main energy storage device and then placing it in the first compartment of the housing member, ensuring safe and secures placement of the main energy storage device in the first compartment of the housing member. Further, the main energy storage device can be easily accessible at the time of servicing or replacement of energy storage device by pulling the cover (401) with holding provisions (403), ensuring ease of accessibility of the component and also decreased serviceability time. As per an embodiment, the outer profile of the energy storage device (404) conforms to the inner circumferential profile of the first compartment (301) thereby enabling ease of lateral assembly or stowing of the energy storage inside the first compartment with suitable guiding means e.g. wedge, roller bearings, dovetail coupling etc.

[00043] Further, as per one embodiment of the present invention, the second compartment (302) of the housing member (134) configure to store various electrical components like an auxiliary energy storage device (408), a motor (409), a controller (407), a battery management system etc. The second compartment (302) of the housing member (134) has various projected portions or ribs or, slots to store and securely locate the electrical components, for example, projected portion (306) is provided in the second compartment (302) to store the motor (409) in the second compartment (302) of the housing member (134). The second compartment (302) is covered by a cover (406) which is detachably attached to the compartment (302) of the housing member (134) with various attachment means for example, fasteners (405). The cover (406) has a slot (402) which conforms with the profile of a shaft (410) present on the motor (409) which is further engaged with suitable transmission means (not shown) to transfer the torque to the wheel. The slot as formed is sealed with a sealing member to avoid entry of dust, mud etc. Therefore, this configuration ensures theft proof accommodation of the electrical components in the housing member. This configuration also ensures ease of accessibility of the electrical components at the time of servicing, thereby reducing the serviceability time of the vehicle. The electrical components are closely packaged, ensuring decreased length of wiring harness, thereby reduced voltage drop and also, increases the life expectancy of the wiring harness. As per one embodiment of the present invention, the housing member (134) is split into two compartments to house the energy storage device in one of the compartments and the other electrical components in the other. As per an alternate embodiment, based on the calibration and tuning requirements of the dynamic behaviour of the vehicle, the energy storage device may be disposed in the bottom compartment. Further, the electrical components may be configured in the top compartment to configure a desirable height of the center of gravity (CG) of the vehicle thereby achieving good handling performance of the vehicle. Therefore, as per an embodiment of the present subject matter, a housing member (134) with modular interior space is created with suitable partition plate and locating rib features. Such a housing member greatly enhances the flexibility for a manufacturer to configure all the components with multiple permutations and combinations while catering to various products variants, performance requirements, mileage range, energy storage capacity while still ensuring a compact vehicle layout, common frame assembly as well as ease of assembly and service of the entire powertrain cum energy storage unit. As per an embodiment of the present invention, the overall volume of the housing member (134) is split into two compartments viz. top compartment T (301) with volume Vt and bottom compartment B (302) with volume Vb. The volumetric ratio of VtVb is in the range of 4:1 to 3:2 which gives an optimum and compact layout towards meeting all objectives outlined earlier.

[00044] The invention helps in overcoming the problem of theft or tampering of the electrical components, reducing wiring harness losses, increasing the accessibility of the electrical components while maintaining the overall weight and width of the vehicle and ultimately makes it cost effective.

[00045] Advantageously, the embodiments of the present invention, describes the potential modifications in the mounting of the housing member to securely place the electrical components. [00046] 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 Assembly 119: Instrument Cluster 127: Head Lamp 200: Frame Assembly 131: Front Fender

129: Front Wheel 130: Front Suspension 134: Housing Member 106: Tail Lamp 132: Seat

138: Rear Fender 133: Rear Wheel Fig. 2

201: Head Tube 202: Main Frame

203: Down Frame 204: Centre Frame 205: Seat Frame

207: Frame Reinforcement Member 208: mounting bracket on down frame.

208a: Provision

210: bracket on Housing Member 209: Profile Fig. 3:

301: First compartment 302: Second compartment 303: Common partition plate 301a: Front Side of first compartment 301a’: outward extending profile

301a”: straight profile 301b: Upper Side of first compartment 301c: Third Side of first compartment 302x: Front side of second compartment 302x’ ’ : Depressed portion on front side of second compartment

302x’: lower end of the front side of second compartment 302y: Lower Side of second compartment 302z: Rear Side 307: Mounting Plate 304: Cross Section Area

305: Cooling Fins 306: Projected Portion Fig. 4

404: Main Energy Storage Device 401 : Cover for first compartment 403 : holding provisions of a cover 402: A slot

406: Cover for second compartment 405: Fasteners

407: Controller

408: Auxiliary Energy Storage Device 409: Motor 410: Shaft.