Frame for electric vehicle

Abstract

A frame for an electric vehicle (10), comprising: a head pipe (12) and at least two rear pipes (13) extending rearward from the head pipe (12); a battery module (24) used as a power source for powering the electric vehicle, comprising at least one battery located below a rear portion (13B) of the rear pipe (13); and a protective frame structure (23) for securely mounting the battery module (24); wherein the protective frame structure (23) is fixed to the rear pipe (13) of the frame and is substantially disposed at the center and below the vehicle.

Description

Technical Field

[0001] The present invention relates to electric vehicles, and more particularly to a frame structure that allows one or more batteries to be packaged within an electric vehicle, particularly a two-wheeled (2W) vehicle. Background Art

[0002] As concerns about climate change and the availability of fossil fuels become evident, a strong trend towards electric vehicle manufacturing and use is now becoming apparent. Electric vehicles include multiple batteries, which include a large number of electrochemical cells. The number of batteries required for an application is primarily driven by the desired vehicle range. Currently, readily available batteries are still bulky, which may limit their use, especially in situations where the desired vehicle range conflicts with a small vehicle size.

[0003] For example, small vehicles that currently operate on liquid and gaseous hydrocarbon fuels could advantageously be converted to electric motor prime movers to reduce emissions. The initial trend to reduce prime mover emissions includes transitioning from gasoline operated engines to gaseous fueled engines, such as LPG or CNG type engines. This reduces emissions. However, changes in regulations, such as proposed in India, are driving the shift to electric vehicles. The timeline for such a transition is short and there are obvious difficulties in reconfiguring the fleet to operate using electric motors. Vehicle redesign and reconfiguration of manufacturing plants for electric vehicle manufacturing is a potentially time consuming and expensive exercise. However, it is desirable to meet the directives / focus set by various governments.

[0004] Batteries are typically expensive, are usually (although not always) intended to be used in packs, and are usually intended to be rechargeable. This creates two problems. First, batteries are susceptible to theft, and it is desirable to utilize the multiple options for anti-theft protection available to avoid this. Second, the expense of high-quality batteries may also create a temptation to replace these batteries with inferior versions that may not include the safety features described below. Battery safety is particularly an issue for 2W vehicles such as motorcycles and scooters. However, there are other non-enclosed electric vehicle types, such as quads and other all-terrain vehicles (ATVs), and battery safety may be an issue for such vehicle types as well.

[0005] Furthermore, the battery needs to be mounted securely and securely on the vehicle so that it is locked in the correct position, thereby not allowing movement in any direction due to vibrations generated during the operation of the vehicle. Using a separate battery box for securely mounting the battery can be used to securely mount the battery. However, such a battery box is bulky and takes up more space. Therefore, floor space / leg room and storage space are taken up, which is one of the basic requirements of a two-wheeled vehicle. The battery is one of the heaviest components in the vehicle. In a two-wheeled vehicle, equal weight distribution along the vehicle is an important criterion because the driver needs to balance the weight in order to balance the vehicle during driving. If the weight distribution within the vehicle is uneven, it is difficult for the driver to maintain balance, which ultimately leads to an unsafe condition. Therefore, the battery also needs to be positioned so that there will be no uneven load acting on the vehicle during operation.

[0006] In this regard, the battery is generally a heavier component and its positioning has a major contribution in determining the overall center of gravity (CG) of the vehicle. For efficient operation, it is always better if the center of gravity of the vehicle is moved towards the lower side of the vehicle. It also improves vehicle handling, safety, and driving comfort. However, the main challenge in moving the battery towards the lower side is that the swing arm has to be moved backwards, which increases the overall length of the vehicle. The size of the battery is another important parameter that determines the capacity of the vehicle. The larger the capacity of the vehicle, the larger the size of the battery.

[0007] Meanwhile, another important component of the vehicle is a storage box, which is generally provided in a two-wheeled vehicle to store any items. The storage space provided in the storage box is also an important feature of any two-wheeled vehicle. The size and mounting position of the battery and other related components ideally should not compromise the space provided in the storage box, even given the requirement for sufficient space available for safely mounting other related components (e.g., charger, motor control unit (MCU), auxiliary battery, etc.).

[0008] The vehicle frame plays an important role in mounting batteries and related components, and obviously, considering the above requirements, it is challenging to provide a frame structure for a two-wheeled vehicle that can safely and securely mount batteries and other related components without compromising vehicle efficiency, safe driving comfort and space for storage boxes in electric vehicles.

[0009] An object of the present invention is to provide a frame for an electric vehicle which enables convenient and secure packaging of the vehicle battery and other related components.

[0010] Another object of the present invention is to provide a frame having a battery mounting position such that the battery does not exert any unbalanced forces, thereby desirably improving the overall efficiency of the electric vehicle with respect to driving comfort.

[0011] It is yet another object of the present invention to provide a frame for an electric vehicle that provides a convenient, compact and low-volume packaging arrangement for the battery and related components so that floor space / leg room and storage space are not compromised. Summary of the invention

[0012] In view of this object, the present invention provides a frame for an electric vehicle, comprising:

[0013] at least one front tube extending from the head tube and at least two rear tubes extending rearwardly from the head tube;

[0014] a battery module, preferably used as a power source for powering the electric vehicle, comprising at least one battery located below the rear tube;

[0015] A protective frame structure for securely mounting the battery module;

[0016] Therein, the protective frame structure for the battery module is fixed substantially centrally below the rear tube of the frame, and the battery module is locked to the protective frame structure from the front and rear sides of the battery module.

[0017] Conveniently, the protective frame structure includes a plurality of cross members that are connected to the rear tube for structural purposes and also allow for a secure and convenient fixation of the battery module. At least one cross member is used to connect the rear tube to produce the protective frame structure. Depending on the design considerations in terms of strength and the components to be included, a front connecting cross member and / or a rear connecting cross member are generally employed, wherein the front cross member connects the rear tube toward the front of the vehicle and the rear cross member connects the rear tube toward the rear of the vehicle to support the battery module. Such cross members are preferably connected to the battery module by a suitable mounting device such as a mounting bracket. The front cross member can extend substantially horizontally above the top surface of the battery to limit any vertical movement of the battery module. The rear cross member can be connected to the rear tube at a position close to the rear side of the frame and conveniently extends downward from the rear tube. A bottom cross member connecting the two rear tubes is provided. The bottom cross member is connected to the rear cross member in a substantially horizontal direction using a connecting member to produce a platform on which the battery can reside securely and is held in place by a locking device with the rear connecting member. Guiding means may be provided on the cross members of the protective frame structure and / or on the battery modules for convenient installation and removal of the batteries to and from the protective frame structure. The guiding means may be in the form of guide rails. The batteries may be removed from either side, rear or centre front of the vehicle for charging or exchange purposes.

[0018] The battery module is connected to the protective frame structure from the front and from the rear by locking devices, with the aim of minimizing vibration, loosening the battery module from the frame to cause either or both of vertical and lateral movement, and preventing theft. Suitable locking devices / brackets can be provided on the front and rear sides of the battery module. Thus, the battery is securely mounted in the protective frame by means of a locking device; no separate battery box is required to securely mount the battery module, thereby not compromising the storage space provided in the storage box. The locking device provided on the rear side of the battery module includes a rear mounting bracket, which is used to lock the battery position from the rear side by clamping the rear mounting bracket to the side bracket from both sides of the battery module, and further locked by clamping the battery module to the side bracket using bolts provided in grooves on the battery module, wherein; the side bracket is fixed to the protective frame structure. The battery fixing structure conveniently includes an opening to enable access to the battery module before connection, and this opening is preferably on the rear side of the battery. The rear side access to the battery makes the battery removal operation difficult, thereby providing more protection from the perspective of theft. Therefore, a horizontal position of the battery is preferred, although vertical positioning can be used. Vibration isolation elements are desirably placed between the battery module and the battery mounting structure to reduce vibrations transmitted to the battery module and reduce user comfort. Preferably, the battery module includes a single battery; however, battery modules including multiple batteries may be used based on power requirements, vehicle design parameters, and space availability.

[0019] The battery module is a relatively heavy vehicle component. For a two-wheeled vehicle, it is highly desirable to have a substantially equal weight distribution along the length of the vehicle so that the driver can balance the weight distribution in order to balance the vehicle during driving. Although it is possible to distribute the weight unevenly within the vehicle, this makes it difficult for the driver to keep the vehicle balanced, which ultimately leads to an unsafe condition. Ideally, the battery or battery module is centrally located along the width of the vehicle, preferably at a central position along the length of the vehicle. The location of the battery plays an important role in defining the center of gravity (CG) of the vehicle, so it is advantageous to move the center of gravity of the vehicle to substantially the same position with the battery in a downward position, desirably below the center of the vehicle. This center of gravity positioning helps to improve the overall efficiency of the vehicle and also provides driving stability, safety and better handling of the vehicle. The battery module is packaged so that when viewed from the side of the vehicle, the battery module does not extend forward beyond the size of the storage box. This ensures that floor space / leg room and storage space are not compromised. Another advantage of such positioning of the battery in the center of the vehicle and the center of the main part of the vehicle's electrical components is that it facilitates the positioning of the wiring harness routing. In addition, since the battery is located in such a downward position, the design length of the swing arm is increased. However, this problem is solved by mounting the motor-transmission assembly on a swing arm, wherein the housing of the motor-transmission itself serves as the required swing arm. Thus, the need for a separate swing arm is eliminated and it helps to achieve compact packaging.

[0020] Conveniently, a storage box is provided that enables storage of items including larger sized items such as helmets. This storage space is separate from the battery storage space and the storage box does not rest directly on the battery surface or on the protective frame structure of the battery. This helps prevent damage to the battery or battery modules.

[0021] Conveniently, the head tube of the vehicle frame allows the installation of handlebars and steering assemblies, and at least one front tube extends backward and downward from the head tube. The front tube of the vehicle frame is also provided with a cross member, which can be an integral part of the front tube or fixed to the front tube separately. Preferably, two rear tubes are attached to the front tube, and the rear tubes extend in the rearward direction of the frame. At least two longitudinal frame members can be arranged on the cross member. The longitudinal member can be a horizontal portion that is substantially horizontal and parallel to each of the two rear tubes. The horizontal longitudinal member and the horizontal portion of the rear tube allow the installation of at least one footrest. One footrest can be installed on the top of the longitudinal member from the top side, while the other footrest can be installed on the bottom of the longitudinal member. The respective sides of the footrest are desirably covered with side members, thereby conveniently creating a hollow space between the two footrests, which is advantageously used for various purposes, such as battery cooling, accommodating other components, etc., as described below.

[0022] During operation (charging / discharging), the battery temperature rises. To obtain maximum efficiency of the battery and extend battery life, the battery is maintained at a desired temperature. Ideally, if the battery temperature exceeds a predetermined limit, battery operation is stopped. Various battery heating and cooling options are available, of which air cooling systems are preferred. Cooling requirements will be more typical, and to this end, the battery is conveniently provided with ram air cooling, wherein the front body panel is configured with one or more vents so that ram air (i.e., airflow through the vehicle during forward motion) flows over the battery and cools the battery.

[0023] The front body panel or guard may house a cooling air duct communicating with the vents and desirably the above-mentioned space between the floor panels. Ram air entering through the vents then flows through the duct and into the hollow space between the floor panels to be directed by the air guide towards the battery for cooling purposes, these components forming an air cooling system. The air guide is conveniently provided on the bottom floor panel. The air cooling system may also include air channels that direct air towards target areas of the battery surface to achieve effective cooling.

[0024] Furthermore, the hollow space formed in the vehicle body panel is advantageously used to place various electrical and electronic components, such as auxiliary batteries, wiring harnesses, etc., which hides the wires and improves the aesthetics of the vehicle. It also keeps the wire connections free from any external threats.

[0025] The frame according to the invention also provides convenient mounting means for other related components (e.g. charger, connection box, motor control unit, DC-DC converter, etc.), which contributes to the optimal packaging of the components in the electric vehicle. The rear pipe is provided with mounting means for mounting the motor control unit (MCU 100), so that the MCU is mounted close to the battery module on the left hand side of the vehicle.

[0026] The MCU is configured to control the amount of torque produced by the motor by controlling the amount of current / voltage supplied based on at least one vehicle operating condition; wherein the amount of current / voltage to be supplied to the motor is determined based on a basic mapping of the amount of power to be supplied to the motor to produce the required torque, the basic mapping being a function of selected vehicle conditions, the selected vehicle conditions including current vehicle speed and / or accelerator pedal or handle position.

[0027] The rear pipe is provided with mounting means for mounting the DC-DC converter at the end of the rear pipe.

[0028] The head pipe is provided with a mounting device for mounting a connection box on the front side of the vehicle; wherein the connection box is configured to receive information including battery information, vehicle speed, driving distance, driving mode, vehicle location, accident information, and is also configured to store the information and share the information with an external device via a suitable communication network including Wi-Fi, Bluetooth, the Internet or a telecommunication network.

[0029] The rear pipe is provided with a mounting device for mounting a charger unit for charging the battery module on the right-hand side of the vehicle.

[0030] The battery modules on the vehicle are charged using a charging cable to connect the charger to an external power source through a charging point, wherein the charging point is disposed on the rear end of the vehicle and is located under the seat so that the charging cable remains plugged in and charges the battery even when the seat is closed and locked. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The electric vehicle of the present invention may be more fully understood through the following description of preferred embodiments of the present invention with reference to the accompanying drawings, in which:

[0032] Figure 1 is a partial isometric view of an electric vehicle according to a first embodiment of the present invention.

[0033] Figure 2 yes Figure 1 A partial isometric view of the frame of an electric vehicle.

[0034] Figure 3 yes Figure 1 A partial side view of a frame of an electric vehicle.

[0035] Figure 4 yes Figure 2 and Figure 3 A partial isometric view of the frame showing the relationship between the rear frame portion and the battery of the electric vehicle.

[0036] Figure 5 yes Figure 1 A partial plan view of the electric vehicle shown.

[0037] Figure 6 yes Figure 1 An isometric view of the frame of an electric vehicle shown

[0038] Figure 7 is from Figure 1 An isometric view of the frame of the electric vehicle shown looking from the rear

[0039] Figure 8 yes Figure 1 and Figure 5 A detailed view of the front body panel of an electric vehicle is shown.

[0040] Fig. 9 yes Figure 1 A schematic side view of the front part of an electric vehicle.

[0041] Fig.10 yes Figure 1 and Figure 5 A partial front view of an electric vehicle.

[0042] Fig.11 yes Figure 1 and Figure 5 A partial side view of an electric vehicle.

[0043] Fig.12 is from Fig. 9 A first detailed side view of the projection, showing the Figure 1 and Figure 5 The rear frame portion of the electric vehicle is related to the motor control unit, DC-DC converter, motor transmission assembly and shock absorber.

[0044] Fig.13 is from Fig. 9 A second detailed side view of the projection showing the motor control unit, shock absorbers and charging point arrangement.

[0045] Figure 14(a) is Figure 1 and Figure 5 Schematic side view of the rear part of an electric vehicle showing the installation of a charger unit and a DC-DC converter according to another embodiment of the present invention.

[0046] Figure 14(b) is Figure 1 and Figure 5 Schematic rear view of the rear part of an electric vehicle showing the installation of a charger unit and a DC-DC converter according to another embodiment of the present invention.

[0047] Fig.15 yes Figure 1 and Figure 5 A schematic isometric view of the rear of an electric vehicle. DETAILED DESCRIPTION

[0048] Reference now Figure 1 , Figure 5 and Figure 7 , an electric vehicle 10 suitable for use as a commuter vehicle is shown having a frame 11 with a head tube 12; a front tube 12A, at least two rear tubes 13. The frame 11 is described in more detail below. The electric vehicle 10 is a two-wheeled scooter including a front wheel 82 and a rear wheel 84. The rear wheel 84 is provided with a swing arm suspension system described further below and a shock absorber 94 provided on the swing arm side of the vehicle 10. The scooter 10 is shown mounted on a conventional form of stand 176.

[0049] The driver steers the electric vehicle 10 via the handlebars 15 including the brake and horn 15A. The driver is protected by the front panel or guard 160 and the front fender 170, and can comfortably place his feet on the floor space 25 formed on the floor 71.

[0050] The electric vehicle 10 has a motor and a transmission system, forming an integrated motor-transmission assembly 208, which includes Figure 1 , Figure 2 , Figure 4 , Figure 5 and Figure 6 A single cell battery module 24 is shown to provide power. The battery module 24 is located at the rear of the vehicle 10, above the motor and drive train 208, in a location that provides a convenient location for routing a wiring harness.

[0051] According to a preferred embodiment, the motor has a rating of 7 kW to 10 kW (although this rating is dictated by the application), and is controlled by a motor control unit (MCU) 100. The batteries 24 are of conventional design, each having a 48 volt rating, and are preferably connected in parallel so that the deliverable voltage is 48 volts.

[0052] The scooter 10 includes the frame 11 as described above and the frame structure supporting the battery module 24 and the motor-drive assembly 208 and other vehicle components. The frame 11 will now be described in further detail, particularly the rear tube 13 thereof including the battery protection frame structure.

[0053] The rear tubes 13 are each connected to the front tube 12A extending downward and rearward, and extend toward the rear side of the vehicle. The front portion 13A of the rear tube 13 includes a pair of horizontally extending tubes 13A. The rear portion of each rear tube 13B extends in the rearward direction of the scooter 10, terminating in a relatively short nearly horizontal position, where the rear tubes 13B converge toward each other and are connected to the cross member 132.

[0054] The key function of the rear frame tubes 13 is to support the battery modules 24 and other related components. The following description shows how these objectives are achieved. The rear frame tubes 13B are connected by three cross members 131, 133 and 134, such as Figures 2 to 5 shown.

[0055] The bottom cross member 133 is connected to the rear tube 13B near its bottom end. The bottom cross member 133 has a portion in the form of a horizontal platform 133A on which the battery module 24 can be easily supported. The vertical plate portion 133C of the cross member 133 prevents the battery module 24 from moving forward.

[0056] The second U-shaped front cross member 131 also connects the rear tube 13B toward its midsection so that when the battery module 24 is secured in place, as further described below, the cross member 131 will limit the chance of removal, particularly by theft, as well as limit vertical movement of the battery module 24.

[0057] The rear connecting member 134 is connected to the rear pipe 13B of the vehicle frame extending in the downward direction, and is connected to the rear mounting bracket 135 which also enables connection to the upper surface of the battery module 24. According to one embodiment, the rear mounting bracket is fixed to the protective frame structure 23 using side brackets 135a on both sides of the battery module 24. The side brackets 135a are fixed to the cross members of the protective frame 23 using the additional brackets 130, such as Figure 4 As shown. Once the battery 24 is installed in the protective frame 23, it is locked in place from the rear side by clamping the rear mounting bracket 135 to the side bracket 135a using nuts and bolts 139c. The battery 24 is provided with at least one groove in which the bolt 139b is installed. The bolt 139c is further clamped to the side bracket 135a. The groove can be used as a guide for removing and adjusting the battery 24 during exchange or replacement. The arrangement of the cross members 131, 133 and 134 is selected to provide sufficient volume to accommodate the battery module 24 and will depend on the rating and size of the battery module 24.

[0058] The rear frame portion 13 and cross members 131, 133, 134 are also configured to leave a rear opening 137 through which the battery module 24 can be positioned. The battery module 24 needs to be securely connected to the rear frame portion 13, and a plurality of locking devices in the form of nut and bolt fasteners are used for this purpose. At the rear end, the battery module 24 is bolted to the rear mounting bracket 135. At the front end, as shown in FIG. Figure 4 As most conveniently shown in FIG. 1 , the battery module 24 is connected to the first front cross member 133C by a connector including bolts 126 that extend the height of the battery module 24 and nuts 125. To provide further security, a locking plate 124 extends from the rear of the battery module 24 to the front of the battery module 24, where the locking plate 124 is connected to the rear mounting bracket 135. At this location, the locking plate 124 is connected to the bolts 126 by nuts 125. The battery 24 is securely mounted in the protective frame 23 by means of the locking device; therefore, no separate battery box is required to securely mount the battery module 24, thereby not compromising the storage space provided in the storage box 105.

[0059] Vibration isolation elements, such as shock absorbers 133B (such as Figure 3 As shown), it is placed between the battery module 24 and the frame 11 to reduce the vibration transmitted from the battery module 24 to the vehicle frame 11.

[0060] The front tube 12A of the vehicle frame 11 is also provided with a cross member 151 which is fixed separately to the front tube 12A. A pair of longitudinal members 150 extending rearward are connected to the cross member 151. The longitudinal member 150 extends substantially horizontally and is parallel to the horizontal portion 13A of each of the two rear tubes 13. The horizontal longitudinal member and the horizontal portion 13A of the rear tube 13B allow a pair of footrests 71 and 73 to be mounted. The footrest 71 is mounted on the top of the longitudinal member 150, and the other footrest 73 is mounted on the bottom of the frame member 150, as shown in FIG. Figure 7 The respective sides of the footrests 71 and 73 are covered by side members, thereby conveniently creating a hollow space 74 between the two footrests 71 and 73, which space 74 is advantageously used for various purposes as described below (as part of the cooling system and for accommodating an auxiliary battery). Figure 6 Further details of the front panel 160 and the foot support portion 71 are shown, the foot support portion including cut-away portions for accommodating the rear frame portion 13 and battery module 24 and other vehicle components.

[0061] The battery module 24 includes a protective frame structure 23. The battery module 24 is installed so that when viewed from the side of the vehicle, it does not extend beyond the size of the storage box 105, such as Fig.12 This ensures that the floor space 25 and the storage space of the storage box 105 are not compromised. The storage box 105 does not rest directly on the battery surface or on the protective frame structure 23, thereby preventing the weight of the luggage placed in the storage box 105 from causing any damage to the battery module 24.

[0062] During operation (charging / discharging), the battery temperature increases. To obtain maximum efficiency of the battery module 24 and extend battery life, the battery module 24 is maintained at a desired temperature. Ideally, if the battery temperature exceeds a predetermined limit, battery operation is stopped. Cooling is often required, and the scooter 10 includes an air cooling system, particularly a ram air cooling system.

[0063] like Figure 8 As shown, the front body panel 160 includes a plurality of vents 162 and 164 to allow ram air (ie, airflow through the vehicle during forward motion) to flow through the battery 24 for cooling purposes.

[0064] The front body panel 160 accommodates cooling air ducts communicating with the vents and desirably accommodating the aforementioned space between the floor panels. Ram air entering through the vents then flows through the ducts and into the hollow space 74 between the floor panels 71 and 73 to be directed by the air guide towards the battery 24 for cooling purposes, these components forming an air cooling system. The air guide is conveniently provided on the bottom floor panel. The air cooling system may also include air channels that direct air towards target areas of the battery surface to achieve effective cooling.

[0065] The operation of the motor (not shown) is controlled by a motor control unit (MCU) 100. The current supplied to the motor must be alternating current, while the current supplied from the battery 24 is direct current; the conversion from direct current to alternating current is also controlled by the MCU 100.

[0066] The MCU 100 determines the amount of torque to be produced by the motor and the corresponding amount of current / voltage to be supplied to the motor based on various vehicle operating conditions. The MCU 100 includes a base map of the amount of power supplied to the motor to produce the required torque as a function of selected vehicle conditions, such as the current vehicle speed and accelerator pedal or handle position. Therefore, if the scooter 10 accelerates or decelerates, its torque requirement changes; similarly, if the total load on the scooter 10 changes during various operating conditions, this reduces or increases the vehicle speed, which changes the torque requirement. Based on the vehicle speed and accelerator pedal position, the required torque is determined from the base map, and the required power (current / voltage) is therefore supplied to the motor under the control of the MCU 100 to produce the required torque.

[0067] like Figure 1 and Figures 9 to 13 As shown, the MCU 100 is located near the battery 24 on the rear side of the vehicle 10, which results in a reduced length of the wiring harness 102 compared to placing the MCU 100 on the front side of the scooter 10. Placing the MCU 100 below the floor panels 71 and 73 will increase the chance of damage due to external impact. As shown, the MCU 100 is mounted on the left hand side of the scooter 10. The MCU 100 is fixed to the vehicle frame using a mounting bracket.

[0068] The scooter 10 includes a series of low voltage electrical components, such as headlights, taillights, horns, indicators, etc. In some cases, these components need to be operated even when the vehicle 10 is not running, although the power requirements of these components are relatively small compared to the motor. Although these components can be operated directly on the power of the main battery 24, it is advantageous to power these components from an alternative low voltage power source, such as an auxiliary battery, which has a lower capacity / rating than the main battery 24. For example, using DC power from the main battery 24 to power low voltage components may cause safety issues. The auxiliary battery can also be used as a safety lock for the vehicle 10 before starting the main battery 24. Conveniently, the auxiliary battery has a capacity of 12V and is very small in size compared to the main battery 24.

[0069] The auxiliary battery is placed in the space created between the floor panels 71 and 73. The top floor panel 71 is provided with a small box-like opening to accommodate the auxiliary battery. A cover 72 fits over the top of the opening to secure the auxiliary battery in place. This conveniently accessible location for maintenance also helps to easily route the vehicle wiring harness.

[0070] like Fig.10 As shown, the DC-DC converter 28 is also mounted on the MCU 100 using a suitable mounting bracket. This helps to reduce the length of the wiring harness. The function of the DC-DC converter 28 is to charge the auxiliary battery by drawing current from the main battery 24. Since the auxiliary battery operates at a much lower voltage than the battery 24, the direct current from the 48-volt main battery 24 cannot be used directly to charge the auxiliary battery. The DC-DC converter 28 reduces the voltage so that the power from the main battery 24 can be used to charge the auxiliary battery. According to another embodiment, as shown in Figures 14(a) and 14(b), the DC-DC converter 28 is packaged at the end of the rear pipe 13 toward the rear side of the vehicle. The DC-DC converter can be appropriately covered by the vehicle covering member.

[0071] Connection box 200, such as Figure 2As shown, it is the core of the electronic system used in the vehicle 10, including communication functions and other electronic and control components. All components in the vehicle 10 are connected through a common CAN type network, where data from various components can be transmitted to the corresponding control unit in digital form. For example, the battery 24 can share information such as its charge state or health state to the connection box 200 through the CAN network. The connection box 200 has a storage medium for storing data received from various components, such as battery information, vehicle speed, driving distance, driving mode, etc. The stored information can be transmitted directly to a mobile device or a remote server / cloud for processing as needed, such as described below. Control software updates can be transmitted in the same way. The connection box 200 has an appropriate communication device, such as Bluetooth, an Internet connection such as Wi-Fi, or a telecommunications network capability using a GSM SIM, or all of these. The connection box 200 also has a GPS transmitter, which helps identify the location of the vehicle. The data sent to the cloud or mobile device can be useful in various means, such as identifying the location of the vehicle, understanding driving patterns, error logs, identifying the need for charging or replacing batteries, etc. This data is also useful from a vehicle repair or maintenance perspective, and can send out regular repair alerts as needed.

[0072] The connection box 200 is located on the front side of the scooter 10, specifically mounted on the head pipe 12, which is a position sufficiently far from the battery 24 and the auxiliary battery to avoid magnetic interference with the electronic components contained in the connection box 200. Considering these factors, including considering the available space, the connection box 200 is preferably placed on the front side of the vehicle 10, which also helps to easily route the wiring harness.

[0073] The scooter 10 also includes an accident sensor (not shown) that senses the vehicle position and identifies accident situations. If any such scenario is detected, an alert signal is sent to the mobile device and also to the cloud with the vehicle position information so that assistance can be given.

[0074] The charger unit 29 is used to charge the battery module 24. It receives an alternating current from an external power source, converts the power into direct current, and supplies power with a specific current voltage to the battery module 24 to charge the battery. The amount of current and voltage, as well as the duration of the current supplied to the battery module 24 for charging purposes, can be fixed using a controller contained in the battery management system. The input is given to the charger through the cable 110, which then controls the power supplied to the battery module 24 according to the instructions received from the battery management system. The control parameters of the battery charger 29 can vary based on the size and number of batteries used. The weight of the charger 29 is also considerable. In order to achieve better balance while driving, the charger 29 is housed on one side of the vehicle, preferably on the opposite side of the ECU 100 position. This positioning helps to balance the weight. Since the charger 29 is fixed to the vehicle 10 itself, its position needs to be safe and fixed to protect from external impact and from theft. To this end, the charger 29 is firmly and fixedly mounted on the vehicle chassis 11 and the rear pipe. The charger 29 is preferably mounted on the opposite side of the MCU 100 to better distribute the weight and achieve better balance. The charger 29 may be mounted to the vehicle frame by means of a suitable bracket.

[0075] Thus, the battery 24 can be charged on the vehicle 10, however, the battery 24 can also be removed for charging. The scooter 10 is provided with a seat 103, such as Fig.12 14. The seat 103 is hinged at one point to allow opening to access the luggage compartment 105 and charging point 129. The positioning of the battery module 24 within the rear frame portion 13 allows the capacity of the luggage compartment 105 to be maximized for the particular scooter 10 and battery module 24 rating and size.

[0076] like Fig.13 As shown, a charging point 129 is provided in the seat 103. To charge the battery 24, the seat 103 is opened, the charger cable 110 is plugged into the charging point 129 and the power source, and charging is started. It may not be preferred to keep the seat 103 open during charging, because the charger 110 needs to be safe from the anti-theft point of view and from the perspective of environmental impact. Therefore, during charging, provision is made so that the seat 103 can be closed and locked, so that the charger 110 remains fixed inside the luggage compartment 105 and cannot be removed without opening the seat 103.

[0077] refer to Figure 9 to Figure 14. The scooter 10 is provided with a rear mono suspension, i.e., only one shock absorber 94 is used to provide the rear suspension, in order to reduce costs. The shock absorber 94 may be of the SNS type as described in the applicant's Indian patent 695 / MUM / 2005, the contents of which are incorporated herein by reference, and the shock absorber is located at the rear of the scooter 10, rather than at the center thereof. A front shock absorber is also provided.

[0078] The shock absorber 94 is connected to the side of the motor-transmission 20 / 80 of the scooter 10 because the load is greater on that side. One end of the shock absorber 94 is bolted to the housing 208C of the motor-transmission assembly 208, while the other end is connected to the rear frame portion 13 through the mounting bracket 13C. The front end of the motor-transmission assembly is mounted at the bracket 198C welded to the protective frame structure 23, while the rear end of the motor-transmission assembly 208 is mounted at the rear axle of the rear wheel 84. The motor-transmission assembly 208 is conveniently described in the applicant's co-pending Indian Patent Application No. 201821047186 filed on December 13, 2019, the contents of which are incorporated herein by reference.

[0079] Fig.15 A schematic rear view of a vehicle according to the invention is shown, wherein the charging cable 110 is led out of the seat 103 in the closed position. The motor-transmission assembly 208 is shown.

[0080] Modifications and variations to the electric vehicle described in this specification may be apparent to a skilled reader of the disclosure. Such modifications and variations are considered to be within the scope of the present invention.

Claims

1. A frame assembly for a two-wheeled electric vehicle (10), the two-wheeled electric vehicle having a battery module (24), the frame assembly comprising: A head pipe (12) and at least two rear pipes (13) extending rearward from the head pipe (12), wherein at least a portion of the at least two rear pipes extends upward toward the rear side of the two-wheeled electric vehicle, and at least a portion of the at least two rear pipes (13B) is continuous with the upwardly extending portion of the at least two rear pipes and extends substantially horizontally toward the rear side of the two-wheeled electric vehicle; A protective frame structure (23) for securely mounting a battery module (24) disposed substantially at the center and below the two-wheeled electric vehicle; The protective frame structure (23) includes a plurality of cross members (131, 133, 134) connected to the upwardly extending portions of the at least two rear tubes (13) from the front, bottom and rear sides, and creates a space for securely mounting the battery module (24), so that at least a portion of the battery module is behind the upwardly extending portions of the at least two rear tubes (13), and at least a portion of the battery module is directly below the substantially horizontal portions of the at least two rear tubes (13B), and wherein the battery module (24) is locked to the protective frame structure (23) from the front and rear sides of the battery module (24).

2. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: At least one of the plurality of cross members (131, 133, 134) is provided with a locking device to securely fix the battery module (24) from the front and rear sides, thereby minimizing vibration and preventing theft.

3. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The locking device arranged on the rear side of the battery module (24) includes a rear mounting bracket (135), which is used to lock the battery position from the rear side by clamping the rear mounting bracket (135) to the side bracket (135a) from both sides of the battery module (24), and further locked by clamping the battery module (24) to the side bracket (135a) using bolts (139b) arranged in grooves (24a) on the battery module (24); the side bracket (135a) is fixed to the protective frame structure (23).

4. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: At least one of the plurality of cross members (131, 133, 134) is provided with a guide device for conveniently installing and removing the battery module (24) from the protective frame structure (23) for charging or exchange purposes.

5. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The protective frame structure (23) is provided with an opening at the front side or the rear side of the two-wheeled electric vehicle (10) for removing the battery module (24) for charging or exchange purposes.

6. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The protective frame structure (23) generates a space for installing the battery module (24) horizontally or vertically inside the protective frame structure (23).

7. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: At least one of the plurality of cross members (131, 133, 134) is provided with a vibration isolation element (133B), and the battery module (24) is mounted on the vibration isolation element to reduce vibration transmitted to the battery module (24).

8. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The protective frame structure (23) creates a space for installing the battery module (24) substantially centrally along the width of the two-wheeled electric vehicle (10) and substantially centrally along the length of the two-wheeled electric vehicle (10).

9. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: A front cross member (131) of the plurality of cross members connects the at least two rear tubes (13) toward the front of the two-wheeled electric vehicle (10); and wherein a rear cross member (134) of the plurality of cross members connects the at least two rear tubes (13) toward the rear of the two-wheeled electric vehicle, and a bottom cross member (133) of the plurality of cross members connects to the rear cross member (134) and the at least two rear tubes (13) in a substantially horizontal direction to create a platform (133A) on which the battery module (24) resides securely.

10. The frame assembly for a two-wheeled electric vehicle (10) according to claim 9, wherein: The front cross member (131) extends substantially horizontally above the top surface of the battery module (24) to limit any vertical movement of the battery module (24); the rear cross member (134) is provided with a rear mounting bracket (135) to further limit the movement of the battery module (24), and the bottom cross member (133) is provided with a first forward cross member (133C) for limiting the forward movement of the battery module (24) using a bolt (126) extending to the height of the battery module and connected to the rear mounting bracket (135) through a locking plate (124).

11. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The protective frame structure (23) provides space for mounting a storage box (105) on the at least two rear tubes (13B) above the battery module (24), so that when viewed from the side of the two-wheeled electric vehicle, the battery module (24) does not extend forward beyond the size of the storage box (105).

12. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The at least two rear tubes (13) are provided with at least two longitudinal frame members (150), which are substantially horizontal and parallel to the horizontal portion (13A) of each of the at least two rear tubes (13), wherein the longitudinal frame members (150) allow foot pedals (71, 73) to be installed, so that one foot pedal (71) is installed on the top of the longitudinal frame member (150) and the other foot pedal (73) is installed on the bottom of the longitudinal frame member (150), and the corresponding sides of the two foot pedals are covered with side members, thereby generating a hollow space (74) between the two foot pedals, which is configured to guide ram air toward the battery module for battery cooling.

13. The frame assembly for a two-wheeled electric vehicle (10) according to claim 12, wherein: The hollow space (74) is created by the horizontal portions of the at least two rear tubes and is provided with mounting means for accommodating an auxiliary battery, a wiring harness or a motor control unit (MCU 100).

14. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The at least two rear pipes (13) are provided with mounting means for mounting a motor control unit (MCU 100), so that the MCU (100) is mounted near the battery module (24) on the left hand side of the electric vehicle (10).

15. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The at least two rear tubes (13) are provided with mounting means for mounting a DC-DC converter (28) at the ends of the rear tubes (13).

16. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The head pipe (12) is provided with a mounting device for mounting a connection box (200) on the front side of the two-wheeled electric vehicle (10).

17. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The rear pipe (13) is provided with a mounting device for mounting a charger unit (29) for charging the battery module (24) on the right-hand side of the electric vehicle.

18. The frame assembly for a two-wheeled electric vehicle (10) according to claim 1, wherein: The protective frame structure (23) is provided with a bracket (198) for mounting the front end of the motor-transmission assembly (208).

19. The frame assembly for a two-wheeled electric vehicle (10) according to claim 18, wherein: The motor-transmission assembly (208) is provided with a housing (208c) serving as a swing arm.

Images