TECHNICAL FIELD

[0001] The present subject matter described herein generally relates to a vehicle with a drive unit, and more particularly but not exclusively relates to a vehicle with a drive unit including a drive unit connector.

BACKGROUND

[0002] Conventionally, an electric vehicle or a hybrid vehicle uses one or more drive units, for example one or more electric motors or traction motors for propulsion. The electrical power source for a two wheeled electric or a hybrid vehicle comprises of a plurality of individual battery cells electrically coupled together and configured to jointly provide power to fulfill the electrical load requirements of the vehicle. The load requirements include either propelling a traction motor of the vehicle, or powering lighting and signaling devices associated with the vehicle, or both. Such electric or hybrid vehicles may be powered through a collector system by electricity from off-vehicle sources, or may be self-contained with a battery, solar panels, fuel cells or an electric generator to convert fuel to electricity. Most large electric or hybrid transport systems are powered by stationary sources of electricity that are directly connected to the vehicles through wires or cables.

[0003] Typically, the electric system of a two wheeled electric or a hybrid vehicle includes one or more battery, one or more motor, one or more motor controller and other electronic equipment. The electricity is stored on board in the rechargeable battery, which drives the one or more electric motors, as a result of which the electric or chemical energy is converted to mechanical energy. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0005] Fig. 1 illustrates a side view of a vehicle when viewed from left hand side of the rider while he is in riding position along with few internal parts of the vehicle for clarity of explanation.

[0006] Fig. 2 illustrates a perspective side view of a vehicle when viewed from left hand side of the rider, showcasing a drive unit connector position with respect to vehicle layout for clarity of explanation

[0007] Fig. 3 illustrates a sub assembly of essential internal components of a vehicle without style panels, in accordance with an embodiment of the present subject matter.

[0008] Fig. 4 illustrates a perspective view of a drive unit connector in accordance with an embodiment of the present subject matter.

[0009] Fig. 5 illustrates a perspective zoomed view of a drive unit connector mounted on a substantial downward region of a controller, in accordance with an embodiment of the present subject matter.

[00010] Fig. 6 illustrates an exploded view of a drive unit connector showcasing the assembly sequence of the drive unit connector with respective to cable connections, in accordance with an embodiment of the present subject matter.

[00011] Fig. 7 illustrates the drive unit connector cable routing in proximity of the swing arm area of the vehicle, in accordance with an embodiment of the present subject matter. DETAILED DESCRIPTION

[00012] Typically, key components of the electric or hybrid vehicle includes the battery, a charge port, a DC/DC converter, an electric traction motor, an on-board charger, a power electronics controller, a thermal system, a traction battery pack and an electric transmission.

[00013] In an electric or hybrid vehicle, an auxiliary battery provides electricity to power vehicle accessories. The charge port allows the vehicle to connect to an external power supply in order to charge the traction battery pack. The DC/DC converter converts higher-voltage DC power from the traction battery pack to the lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary battery. The traction battery pack stores electricity for use by the electric traction motor. Using power from the traction battery pack, the electric motor drives the vehicle's wheels. Some vehicles use motor generators that perform both the drive and regeneration functions. The onboard charger takes the incoming AC electricity supplied via the charge port and converts it to DC power for charging the traction battery. It also communicates with the charging equipment and monitors battery characteristics such as voltage, current, temperature, and state of charge while charging the battery pack. The Power electronics controller unit manages the flow of electrical energy delivered by the traction battery, controlling the speed of the electric traction motor and the torque it produces. The thermal system maintains a proper operating temperature range of the power train, the electric motor, the power electronics, and other components. And the transmission transfers mechanical power from the electric traction motor to drive the wheels.

[00014] Some known arts disclose a brushless DC motor being fixed to a hub of a rear wheel of the two wheeled electric vehicle. Particularly, in saddle-ride type electric vehicle, in which the battery is disposed under a floor board, the motor and a speed reduction gear are accommodated at a swing arm which rotatably supports the shaft of the rear wheel.

[00015] Other known arts disclose, the traction motors typically being a three phase brush less motor, sometimes also having an angle sensor to sense the instantaneous phase of the brush less motor.

[00016] Some other known arts disclose that for the purpose of electrical supply, a wiring or cable harness of a traction motor from each phase of the motor, is guided through or along the swing arm and connected with a power source. Therefore, in such known arts, the wiring or cable harness is required to be disconnected and removed in order to service nearby or underlying parts, for example, the motor or the wheel, making serviceability a cumbersome process. Moreover, in order to access the wiring or cable harness one requires removal of style panels and wire or cable fixing clamps.

[00017] Also, after servicing, the reassembly of all the removed parts and the wiring or cable harness on their respective original positions can be a daunting process. This is because while reassembling, sometimes service mechanics make reverse or cross connections of the wiring or cable harness of the three-phase motor, which either results in reverse operation of motor resulting into lowering of the overall motor efficiency. Moreover, frequent removal of the style panels for the purpose of serviceability and error estimation can contribute to deterioration and damage of the style panels.

[00018] In order to avoid such reverse or cross connections of the wiring or cable harness of the three-phase motor, some known arts disclose usage of a single pole connector for each phase. However, usage of such single pole connector often creates arcing between mating connectors due to vehicle vibration which results into overall considerable power loss. Also, frequent removal of such single pole connector, after few numbers of mating cycles results into increasing of the contact resistance between the connectors, which ultimately results in drastic reduction of the overall efficiency of the traction motor. [00019] Hence, there is a need to provide an optimal layout positioning of a drive unit connector addressing above circumstances and problems of the known arts.

[00020] The present subject matter has been devised in view of the above circumstances as well as solving other problems of the known art.

[00021] The present subject matter relates to a vehicle comprising one or more controller, with one or more drive unit, for example, a motor, and one or more drive unit connector.

[00022] As per an aspect of the present embodiment, the one or more drive unit connector, for example one or more motor connector, is mounted in a first space, adjoiningly ahead of one or more controller, and disposed below a seat unit and substantially above a floor board of the vehicle.

[00023] As per another aspect of the present embodiment, the one or more drive unit connector is covered by a front panel of the vehicle. Therefore, the drive unit connector is capable of being accessed by removing only the front panel of the vehicle.

[00024] As per another aspect of the present embodiment, a first bracket is mounted on one of the controller and a second bracket is further mounted on at least one end of the first bracket facing towards the ground. The one or more drive unit connector is further mounted on the second bracket through an extended part by means of welding or by means of one or more fastening means. The extended part is an extended portion of the one or more drive unit connector.

[00025] As per another aspect of the present embodiment, the one or more drive unit connector includes a first part and a second part.

[00026] As per another aspect of the present subject matter, the second part of the drive unit connector includes a plurality of ribbed regions located in between the detachably attached cables. [00027] As per another aspect of the present embodiment, the second part of the drive unit connector includes a plurality of ridges located on the sides of the second part of the drive unit connector.

[00028] As per another aspect of the present embodiment each of the plurality of cables is detachably attached to the first part by means of a fixing mechanism. The fixing mechanism includes at least one of the stud(s) being attached on the first part of the drive unit connector. At least one of the stud(s) receives at least one of the ring terminals from the cable(s) harness. At least one of the ring terminal(s) from cable harness receives at least a ring terminal(s) from the drive unit side. The at least one of the ring terminal(s) from drive unit side receives at least one of the cable(s), wherein at least one of the cable(s) is detachably attached by means of at least one of the lock nut(s).

[00029] As per another embodiment of the present subject matter, a battery unit is disposed below the floor board of the vehicle.

[00030] As per another embodiment of the present subject matter the battery unit supplies power to the drive unit of the vehicle via of a plurality of cables connected by the drive unit connector. The plurality of the cables is enclosed within a cable casing and the cable casing is clamped at one or more positions by means of one or more cable clamps.

[00031] As per another embodiment of the present subject matter, one or more controller is mounted on a single integrated bracket. The integrated bracket is further mounted on a frame assembly of the vehicle.

[00032] As per another embodiment of the present subject matter, at least two fixing or mounting points are provided on the extended part of the drive unit connector, such that the extended part aids in mounting of the drive unit connector on at least two points of the second bracket. Such mounting provision aids in enabling anti- rotation of the drive unit connector and resultantly aids in keeping the drive unit connector in position rigidly, while negating the effect of the vehicle vibration.

[00033] Exemplary embodiments detailing features regarding the aforesaid and other advantages of the present subject matter will be described hereunder with reference to the accompanying drawings. Various aspects of different embodiments of the present invention will become discernible from the following description set out hereunder. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. 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. Further, it is to be noted that terms “upper”, “down”, “right”, “left”, “front”, “forward”, “rearward”, “downward”, “upward”, “top”, “bottom”, “exterior”, “interior” and like terms are used herein based on the illustrated state or in a standing state of the two wheeled vehicles with a driver riding thereon. Furthermore, arrows wherever provided in the top right corner of figure(s) in the drawings depicts direction with respect to the vehicle, wherein an arrow F denotes front direction, an arrow R indicates rear direction, an arrow Up denotes upward direction, an arrow Dw denotes downward direction, an arrow RH denotes right side, and an arrow FH denotes left side. 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.

[00034] Fig. 1 illustrates a side view of a vehicle 100 when viewed from left hand side of the rider while he is in riding position along with few internal parts of the vehicle for clarity of explanation. The saddle ride type vehicle 100 includes a front frame 103, a central frame 104 and a rear frame 105 joined together to form the frame assembly 102. The front frame 103 of the frame assembly 102 is steerable by the rider, and a handle bar unit 109 comprising of a left handle bar grip 110 and a right handle bar grip (not shown) is used by the rider to steer a front wheel 108 of the vehicle 100 in the desired direction. A front suspension unit 112 is present on the front portion of the vehicle 100 for smooth force transmission to the front wheel 108, and a rear suspension unit (not shown) for smooth force transmission to the rear wheel 107.

[00035] The front frame 103 of the frame assembly 102 includes a head tube (not shown) and a down tube (not shown); the head tube supports the front suspension unit 112, which further supports the handle bar unit 109 in a steerable manner and the down tube extends rearward and downward of the head tube. The central frame 104 has two tubes (not shown) on the left and right of the vehicle (100) extending away from each other and running substantially parallel in a rearward direction. The left and right tubes are connected by one or more cross frame (not shown) extending in vehicle width direction. These left and right tubes further extend rearward and upward to form the rear frame 105, which supports other units of the vehicle 100 at rear portion.

[00036] A front panel 116 is provided ahead of the head tube for covering the head tube when viewed from front of the vehicle 100. A rear panel 117, extending downwards from the head tube, covering the head tube and down tube from the rear side. A front fender 119 is provided above the front wheel 108, in the vicinity of the front suspension unit 112, to prevent mud splashing onto the internal components of the vehicle 100 at front portion. A handle bar rear panel 120, at least partly covers the handle bar unit 109, from the rear side of the vehicle 100. A handle bar front panel 121 at least partly covers the handle bar unit 109 from front side of the vehicle 100. A glove box 118 is mounted on the rear panel 117, below the handle bar rear panel 120 and above a floor board 124. A headlamp unit 122 is disposed on the handle bar front panel 121 and mirror units 123 are disposed on the handle bar unit 109 through the handle bar front panel 121. An interfacing portion of the handle bar front panel 121 and the handle bar rear panel 120 has a cut-out zone (not shown) on left side and right side for projecting the left handle bar grip 110 and right handle bar grip (not shown) respectively. The floor board 124 as leg resting panel is provided above the central frame 104 to cover a top portion of the central frame 104 and a bottom panel 125 is provided below the central frame 104 to cover a bottom portion of the central frame 104.

[00037] On the rear side, a utility unit 126 is disposed, at the space between the left and right tubes at the rear portion of the vehicle 100 above the space in between the floor board 124 and the rear wheel 107, to store articles. The utility unit 126 is mounted onto the cross tube at the front zone and rear zone, thus getting supported by the rear frame 105 of the frame assembly 102 of the vehicle 100. A seat unit

127 is provided, above the utility unit 126 and extends throughout the rear frame 105, for the rider to sit over and maneuver the vehicle 100. The seat unit 127 is mounted onto the vehicle 100 through a hinge unit 128, provided on the utility unit 126, such that the seat unit 127 can be opened by rotating it about the hinge unit

128 to provide access to the storage area 129 of the utility unit 126.

[00038] A side panel unit 130 is provided on the left and right sides of the rear frame 105 so as to cover the internal components when viewed from left side of the vehicle 100 and right side of the vehicle 100 respectively. A front cover 131 is disposed ahead of the utility unit 126 and below the seat unit 127 to cover the internal components, such as the frame assembly 102 in a vehicle perspective view. A rear cover 132 is provided rearward to the rear frame 105 and an opening (not labeled), formed by assembling of the rear cover 132 and the side panel unit 130, is used to place a tail lamp unit 133 on the rear side of the vehicle 100. A rear fender 134 is disposed above the rear wheel 107 to prevent mud splashing onto internal components while riding. A grab rail 135 is disposed in the vicinity of the seat unit 12, on the rear portion of the vehicle 100, to enable a pillion rider to grab for support.

[00039] The vehicle 100 further includes one or more battery unit 115 (shown in Fig. 3), one or more drive unit 137 (shown in Fig. 2), for example an electric motor, and a controller 106 (shown in Fig. 3). The battery units 115 may be a mobile battery units or chargeable secondary battery unit, for example, a lithium-ion battery, a nickel hydrogen battery, and the like.

[00040] Fig. 2 illustrates a perspective side view of a vehicle 100 when viewed from left hand side of the rider, showcasing a drive unit connector 140 (shown in Fig. 3) position with respect to vehicle 100 layout for clarity of explanation. The vehicle 100 includes a drive unit 137, for example, a motor mounted on a rear wheel 107 of the vehicle 100. One or more drive unit connector 140 is substantially mounted in a first space 136 of the vehicle, shown by dotted lines. The first space 136 is present below a seat unit 127 and substantially above a floor board 124 of the vehicle 100. The one or more drive unit connector 140 adjoins one or more controller 106 (shown in Fig. 3); and disposed below a seat unit 127 and substantially above a floor board 124 of the vehicle 100. The drive unit connector 140 is connected to the drive unit 137 by means of plurality of cables, enclosed in a cable casing 138.

[00041] Fig. 3 illustrates a sub assembly of essential internal components of a vehicle 100 without style panels, in accordance with an embodiment of the present subject matter. The present figure illustrates a rear portion of the frame assembly of 102 of the vehicles 100 in accordance with the present embodiment. The rear portion includes a pair of rear suspension unit 113. A middle portion of the vehicle 100, just before the rear portion includes a battery 115 disposed below a floor board (shown in Fig. 2) of the vehicle 100. The battery 115 acts as a power unit for the vehicle 100 and supplies power to the traction motor (drive unit) 137 (shown in Fig. 2) of the vehicle by means of plurality of cables 138c (shown in Fig. 6) connected to the drive unit connector 140. The drive unit 137 is mounted on a rear wheel 107 (shown in Fig. 1) of the vehicle 100. The pluralities of cables 138c are enclosed within a cable casing 138, in order to keep the plurality of cables 138c together. The plurality of cables 138c within the cable casing 138 is routed along the proximity and substantially along a swing arm 114 of the vehicle 100 and is connected to one end to the drive unit 137.

[00042] One or more controller 106 is mounted on an integrated bracket 152, wherein the integrated bracket 152 is mounted on a middle portion of the frame assembly 102 of vehicle 100. The drive unit connector 140 is mounted in proximity of the controller 106 and below the lowermost portion of the controller 106, such that the drive unit connector 140 is mounted on a bottom portion of the controller 106. The drive unit connector 140 is configured such that it is capable of being opened vertically towards the ground (as shown in fig 5) to enable ease of wiring harness routing and connections.

[00043] Fig. 4 illustrates a perspective view of a drive unit connector 140 assembled in the vehicle in accordance with an embodiment of the present subject matter. The drive unit connector 140 is disposed in a first space 136 (shown in Fig. 1) present ahead of a controller 106 (shown in Fig. 3). The drive unit connector 140 comprises of a first portion 140a and a second portion 140b.

[00044] The first portion 140a is mounted on the controller 106 and includes plurality of cables 138c detachably attached. The plurality of cables 138c are guided together in a cable casing 138 by means of a cable guide 141 which is disposed towards the lateral edge of the first portion 140a. The second portion 140b acts as a cover for the first portion 140a of the drive unit connector 140. The second portion 140b is capable of being swiveled and opened downwardly in a direction towards the ground and away from the first part 140a with its axis of rotation being substantially in a lateral direction of the vehicle.

[00045] Fig. 5 illustrates a perspective zoomed view of a drive unit connector 140 mounted on a substantial downward region of a controller 106, in accordance with an embodiment of the present subject matter. A first bracket 150 is attached to the one or more controller 106, wherein a second bracket 151 is attached substantially on at least one end of the first bracket 150. Further, one or more drive unit connector 140 is mounted on the second bracket 151 through an extended part 139 (shown in Fig. 6), wherein the extended part 139 is an extended portion of the one or more drive unit connector 140.

[00046] The one or more drive unit connector 140 is mounted on the second bracket 151 through an extended part 139 by means of at least two mounting provisions present on the second bracket. The one or more drive unit connector 140 is mounted on the second bracket 151 through the extended part 139 by means of welding or by means of one or more fastening means. Such mounting provision aids in achieving anti-rotation of the drive unit connector 140 and resultantly aids in keeping the drive unit connector 140 in position rigidly, while negating the effect of the vehicle 100 vibration when the vehicle 100 is in motion.

[00047] The drive unit connector 140 includes a first portion 140a and a second portion 140b. The first portion 140a enables secure routing a plurality of cables 138c through a plurality of lock nuts 146, a plurality of studs 147, and a plurality ring terminal 145.

[00048] The plurality of cables 138c are detachably attached to the first portion 140a by means a fixing mechanism. The fixing mechanism includes at least one of the studs 147 (shown in Fig. 6) attached on the first portion 140a, wherein at least one of the studs 147 receives at least a ring terminal 145 from cable harness 145a. The at least one of the ring terminals 145 from cable harness 145a receives at least a ring terminal 145 from the drive unit side 145b; wherein the at least one ring terminal from the drive unit side 145b receives at least one cable 138c. The at least one of the cables 138c is detachably attached by means of at least one of the lock nuts 146.

[00049] The pluralities of cables 138c include plurality of input cables 138a and plurality of output cables 138b. The plurality of output cables 138b is guided together in a cable casing 138 (shown in Fig. 7) by means of a cable guide 141. The cable casing 138 further is routed in the proximity and along the swing arm 114 (shown in Fig. 3) and is connected to the drive unit 137 mounted on the rear wheel 107 (shown in Fig. 1) of the vehicle 100.

[00050] The second portion 140b of the drive unit connector 140 includes plurality of ribbed regions 143 between the phase terminals of the cables 138c. In drive unit connector 140 the plurality of ribbed regions 143 between the phase terminals of the cables 138c to avoid anti-rotation of the drive unit connector 140 and to provide rigidness to the drive unit connector 140 during vehicle 100 vibration.

[00051] Further, the second portion 140b of the drive unit connector 140 includes plurality of ridges 144. The plurality of ridges 144 provides stable and tight packaging of the drive unit connector 140, while ensuring the safe passage for the plurality of input cables 138a and the plurality of the output cables 138b.

[00052] Fig. 6 illustrates an exploded view of a drive unit connector 140 showcasing the assembly sequence of the drive unit connector 140 with reference to connections of one or more cable 138c, in accordance with an embodiment of the present subject matter. The drive unit connector 140 includes a first portion 140a and a second portion 140b. The first portion 140a includes a plurality of cables 138c, a plurality of lock nuts 146, a plurality of studs 147, and a plurality ring terminal 145 (shown in Fig. 5). [00053] The plurality of cables 138c is detachably attached to the first portion 140a by means a fixing mechanism. The fixing mechanism includes at least one of the studs 147 attached on the first portion 140a, wherein at least one of the studs 147 receives at least one ring terminal 145 (shown in Fig. 5) from cable harness 145a. The ring terminal 145 includes at least one ring terminal from cable harness 145a and at least a ring terminal from drive unit side 145b. At least one ring terminal from cable harness 145a receives at least one ring terminal from the drive unit side 145b. Further, at least one cable 138c is received by at least one ring terminal from the drive unit side 145b. Then the at least one cable 138c is detachably attached to the at least one ring terminal from the drive unit side 145b by means of at least one lock nut 146.

[00054] The second portion 140b includes plurality of ridges 144 present on the side regions of the second portion 140b. An extended portion 139 protrudes upwardly from at least one end of the first portion 140a of the drive unit connector 140. Drive unit connector 140 being mounted on the second bracket 151 through the extended part 139 by means of at least two mounting provisions present on the second bracket 151. Such mounting provision aids in achieving anti-rotation of the drive unit connector 140 and resultantly aids in keeping the drive unit connector 140 in position rigidly, while negating the effect of the vehicle 100 vibration which tend to undesirably loosen the wiring harness over period of time leading to poor reliability.

[00055] Fig. 7 illustrates the drive unit connector cable 138c (shown in Fig. 6) routing in proximity and along the swing arm 114 of the vehicle 100, in accordance with an embodiment of the present subject matter. The plurality of cables 138c (shown in Fig. 6) guided by the cable guide 141 (shown in Fig. 5) are enclosed within a cable casing 138.

[00056] Since the cable guide 141 guides the plurality of cables 138c (shown in Fig. 6) by providing dedicated slots for each cable 138c, therefore the cable guide 141 ensures elimination of cross connection or faulty connections of the plurality of cables 138c. Therefore, allowing multiple removals of electrical contacts as an when required for service and repair.

[00057] The cable casing 138 is further routed along a swing arm 114 towards a drive unit 137 mounted on a rear wheel 107 of the vehicle 100. The cable casing 138 is further clamped by a plurality of cable clamps, wherein the plurality of cable clamps includes a first cable clamp 148 and a second cable clamp 149.

[00058] Further, the drive unit connector 140 (shown in Fig. 2) is disposed behind and in close proximity of the front covers 131 of the vehicle 100 substantially above the floor board 124 and below the seat unit 127. The front cover 131 acts as a protective cover for the drive unit connector 140 while ensuring easy serviceability of the drive unit connector 140. This is possible because, during serviceability, the user can easily remove the front cover 131 of the vehicle 100 and quickly access the drive unit connector 131 configured in close vicinity of the front cover 131 and inside the cover 131. Therefore, any failure in controller or drive unit can be identified directly in traction motor connector by removal of front cover 131 without disturbing other major style parts of the vehicle 100.

[00059] The fixing mechanism of the drive unit connector 140 along with the usage of cable guide and cable clamping enables frequent removal of the plurality of cables or phase terminals without losing or adversely deteriorating the contact resistance in between them.

[00060] Many modifications and variations of the present subject matter are possible in the light of above disclosure. Therefore, within the scope of claims of the present subject matter, the present disclosure may be practiced other than as specifically described. LIST OF REFERENCE NUMERALS

100- Vehicle 25 121- Front panel

102- Frame assembly 122- Headlamp unit

103- Front frame 123- Mirror unit

104- Central frame 124- Floor board 105- Rear frame 125- Bottom panel

107- Rear wheel 30 126- Utility unit 106- Controller 127- Seat unit

108- Front wheel 128- Hinge unit

109- Handle bar unit 129- Storage area 110- Left handle bar grip 130- Side panel unit

112- Front suspension unit 35 131- Front cover

113- Rear suspension unit 132- Rear cover

114- Swing arm 133-Tail lamp unit

115- Battery 134- Rear fender 116- Front panel 135- Grab rail

117- Rear panel 40 136- First space

118- Glove box 137- Drive unit

119- Front fender 138- Cable casing

120- Handle bar rear panel 138a- Input Cable 138b- Output Cable 145b- Ring terminal from drive unit side

138c- Cable

146- Lock nut

139- Extended part

20 147- Stud

140- Drive unit connector

148- First Cable clamp

140a- First part

149- Second cable clamp 140b- Second part

150- First bracket

141- Cable guide

151- Second bracket

143- Ribbed region

25 152- Integrated bracket

144- Ridges

145- Ring terminal 145a-Ring terminal from Cable harness