An integrated wheel hub motor system with AI-controlled control system and advanced cooling mechanism

Abstract

An integrated wheel hub motor system with AI-controlled management system and advanced cooling mechanism, consisting of: a magnetless switched reluctance motor (SRM) comprising a stator with three-phase concentrated copper windings and a magnetless rotor, wherein the motor can be operated with variable three-phase voltage and current; a planetary gearbox integrated into a motor housing hub comprising: a sun gear directly coupled to the SRM rotor, several planet gears, a ring gear and a carrier plate for mounting the planetary gearbox, the motor housing hub being configured to enclose the magnetless switched reluctance motor and the planetary gearbox and to support the mounting of a rim and tire assembly; a liquid cooling system comprising liquid-cooling, serpentine tubes arranged around the stator and configured to circulate liquid coolant for heat regulation; a large number of sensors configured to monitor engine temperature, speed, torque and vibration in real time; an AI-based control module configured to: receive real-time data from a variety of sensors; dynamically adjust engine parameters such as torque, speed, and thermal management based on the received data; optimize energy consumption by adapting engine operation to varying terrain, load, and driving conditions; and control the coolant flow rates of the liquid cooling system based on engine temperature, speed, and load; and an IoT connectivity module configured to transmit sensor data to a cloud-based platform for predictive maintenance and performance tracking.

Description

AREA OF INVENTION

[0001] The present disclosure relates to the field of drive systems for electric vehicles, in particular an integrated wheel hub motor system with an AI-controlled control system and an advanced cooling mechanism. More specifically, the present invention relates to an advanced wheel hub motor system for two-wheeled vehicles, comprising AI-controlled control systems, advanced cooling mechanisms, and planetary gears for improving efficiency, performance, and reliability. BACKGROUND OF THE INVENTION

[0002] Switched reluctance motors (SRMs) have proven to be a promising alternative to permanent magnet motors for two-wheel applications due to their simple design, high reliability, and cost-effectiveness. Unlike permanent magnet motors, SRMs do not require rare-earth magnets and are therefore environmentally friendly and economical. However, their introduction into wheel hub motors has been significantly hampered by three critical engineering challenges.

[0003] First, thermal management within the limited hub space presents a major challenge. The restricted space in hub motors makes effective heat dissipation difficult, leading to overheating and a reduced lifespan. Existing cooling solutions have proven inadequate for maintaining optimal operating temperatures under varying load conditions.

[0004] Secondly, conventional SRM hub motors suffer from insufficient torque delivery at low speeds, which negatively impacts acceleration performance and ride comfort. This limitation is particularly problematic for two-wheelers that require responsive acceleration from a standstill.

[0005] Thirdly, the mechanical integration of key components such as planetary gears and cooling systems into the compact hub design presents a significant technical challenge. While previous developments have addressed these components independently, none of the existing solutions have successfully integrated all three systems – SRM, planetary gears, and liquid cooling – into a single compact hub motor assembly.

[0006] Furthermore, current hub motors lack intelligent control systems that enable real-time performance optimization, predictive maintenance, and fault diagnosis. The absence of adaptive control mechanisms leads to suboptimal energy efficiency and increased maintenance requirements.

[0007] To overcome the aforementioned challenges, the present invention offers an integrated magnetless SRM wheel hub motor system that combines advanced thermal management, improved torque transmission through planetary gears and AI-controlled regulation in a compact, reliable design specifically optimized for two-wheel applications. Summary of the invention

[0008] The present disclosure relates to an integrated wheel hub motor system with an AI-controlled control system and an advanced cooling mechanism. Specifically, the present invention provides an integrated magnetless reluctance wheel hub motor system that combines a planetary gearbox and AI-controlled liquid cooling in a single compact assembly. The system utilizes artificial intelligence to dynamically optimize motor performance by monitoring operating parameters in real time and adjusting torque, speed, and thermal management accordingly. The integrated planetary gearbox improves torque delivery at low speeds, while the liquid cooling system maintains optimal operating temperatures through intelligent coolant flow control. IoT connectivity enables predictive maintenance and remote monitoring, thus significantly improving the reliability and operational efficiency of two-wheeler applications.

[0009] The present disclosure aims to provide an integrated wheel hub motor system with an AI-controlled control system and an advanced cooling mechanism. The system comprises: a magnetless switched reluctance motor (SRM) with a stator having three-phase concentrated copper windings and a magnetless rotor, wherein the motor can be operated with variable three-phase voltage and current; a planetary gearbox integrated into a motor housing hub, comprising a sun gear directly coupled to the SRM rotor, several planet gears, a ring gear, and a carrier plate for the planetary gearbox, wherein the motor housing hub encloses the magnetless switched reluctance motor and the planetary gearbox and supports the assembly of a rim and tire assembly; a liquid cooling system comprising liquid-cooled, serpentine tubes positioned around the stator, circulating liquid coolant for thermal regulation;Multiple sensors for real-time monitoring of engine temperature, speed, torque, and vibration; an AI-based control module for receiving real-time data from the multiple sensors; dynamically adjusting engine parameters such as torque, speed, and thermal management based on the received data; optimizing energy consumption by adapting engine operation to different terrain, load, and driving conditions; controlling coolant flow rates of the liquid cooling system based on engine temperature, speed, and load; and an IoT connectivity module configured to transmit sensor data to a cloud-based platform for predictive maintenance and performance tracking.

[0010] One objective of the present disclosure is to provide an integrated wheel hub motor system with an AI-controlled control system and an advanced cooling mechanism.

[0011] Another objective of the present disclosure is to implement AI-driven control mechanisms that enable real-time performance optimization, predictive maintenance and fault diagnosis, thereby extending the service life and reducing maintenance requirements.

[0012] Another objective of the present disclosure is to provide an integrated wheel hub motor system that addresses the challenges of thermal management, torque delivery and mechanical integration in a compact design specifically optimized for two-wheel electric vehicles.

[0013] Another objective of the present disclosure is to provide a cost-effective and environmentally friendly alternative to permanent magnet motors by utilizing magnetless reluctance motor technology while achieving superior performance through the intelligent integration of mechanical and thermal management systems.

[0014] To further clarify the advantages and features of the present disclosure, the invention is explained in more detail with reference to specific embodiments illustrated in the accompanying drawings. These drawings merely show typical embodiments of the invention and are therefore not to be understood as limiting its scope. The invention is described and explained more precisely and in greater detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE FIGURES

[0015] These and other features, aspects, and advantages of the present disclosure will be better understood if the following detailed description is read with reference to the accompanying drawings, in which identical symbols consistently represent identical parts. The following applies: Fig. Figure 1 shows a diagram illustrating the magnetless SRM in a wheel hub motor with integrated planetary gear and liquid cooling according to an embodiment of the present disclosure; Fig. Figure 2 shows an architecture diagram of the bidirectional motor control unit with integrated battery charge controller according to an embodiment of the present disclosure. Fig. Figure 3 shows a block diagram of an automatic gearshift mechanism according to an embodiment of the present disclosure. Fig. Figure 4 shows a block diagram of an AI-based enhanced liquid cooling system according to an embodiment of the present disclosure. Fig. Figure 5 shows a block diagram of an integrated wheel hub motor system with AI-controlled control system and advanced cooling mechanism according to an embodiment of the present disclosure.

[0016] Experts will also recognize that the elements in the drawings are presented for the sake of simplicity and are not necessarily to scale. For example, the flowcharts illustrate the process by highlighting the main steps to enhance understanding of the aspects of this disclosure. Furthermore, with regard to the design of the device, one or more components of the device may be represented in the drawings by conventional symbols, and the drawings may show only the specific details relevant to understanding the embodiments of this disclosure, so as not to clutter the drawings with details that are readily apparent to those skilled in the art after reading this description. DETAILED DESCRIPTION:

[0017] For a better understanding of the inventive principles, reference is made below to the embodiment shown in the drawings, which is described in specific language. However, this does not limit the scope of the invention. Changes and further modifications of the illustrated system, as well as further applications of the inventive principles, are possible, as would normally occur to a person skilled in the art in this field.

[0018] It is clear to the person skilled in the art that the preceding general description and the following detailed description are exemplary and explanatory of the invention and are not intended as a limitation of it.

[0019] References in this specification to “an aspect”, “another aspect”, or similar expressions mean that a particular feature, structure, or property described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, occurrences of the expressions “in one embodiment”, “in another embodiment”, and similar expressions in this specification may all refer to the same embodiment, but need not.

[0020] The terms "includes," "include," or other variations thereof are intended to cover non-exclusive inclusion, such that a process or method that includes a list of steps may not only contain those steps but may also include other steps not expressly listed or inherent in such process or method. Likewise, the statement "includes..." in the case of one or more devices, subsystems, elements, structures, or components does not, without further limitations, preclude the existence of other devices, subsystems, elements, structures, components, or additional devices, subsystems, elements, structures, or components.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as understood by a person skilled in the art in the field of the invention. The system, methods, and examples provided here serve only for illustration and are not to be construed as a limitation.

[0022] Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0023] The present invention relates to an integrated wheel hub motor system that combines a magnetless SRM with a compact planetary gearbox and an AI-controlled liquid cooling system to improve torque output, optimize heat dissipation, and increase overall operating efficiency. The system's artificial intelligence and machine learning capabilities enable dynamic monitoring and adjustment of motor parameters, predictive maintenance, real-time fault diagnosis, and intelligent energy management. The system is also integrated with IoT connectivity, enabling continuous performance monitoring and user feedback. The present invention addresses thermal, torque, and integration challenges simultaneously, providing a high-performance, durable, and intelligent wheel hub motor solution, particularly for modern electric two-wheelers.

[0024] The main objective of the present invention is to provide a wheel hub motor system that combines a magnetless reluctance motor (SRM) with an advanced planetary gearbox and AI-controlled liquid cooling. This optimizes thermal management, torque delivery, and the operating efficiency of electric two-wheeled vehicles. A further objective of the invention is the implementation of artificial intelligence (AI) for real-time monitoring and adjustment of critical motor parameters such as torque, speed, and temperature to improve the overall performance, efficiency, and reliability of the motor system. Another objective of the invention is the use of an integrated planetary gearbox to improve torque and acceleration at low speeds, thereby achieving higher torque output than conventional hub motors.A further objective of the invention is the use of AI-controlled liquid cooling to maintain optimal motor operating temperatures, prevent overheating, and ensure reliable performance under varying load and environmental conditions. Another objective is the use of AI and Internet of Things (IoT) platforms for predictive maintenance to detect potential faults early and reduce the risk of unexpected motor failures. A further objective is improved energy management through dynamic adjustment of motor operation using AI algorithms. This increases energy efficiency and reduces power consumption, particularly under low-torque operating conditions.A further objective of the invention is the continuous data acquisition and performance monitoring via IoT and wireless cloud storage, providing real-time insights into the condition and operating state of the motor. Another objective is the provision of a user-friendly interface, accessible via mobile applications or web platforms, enabling users to monitor system performance, receive error messages, and easily schedule maintenance. A further objective is the integration of sensor-based data acquisition, where sensors capture real-time information on parameters such as temperature, speed, and vibration, which is then processed by AI for performance optimization.A further objective of the invention is intelligent fault diagnosis using AI algorithms that can identify faults and suggest predictive maintenance measures to prevent failures and extend the motor's service life. Another objective is the seamless integration of the planetary gear into the motor housing, thereby increasing torque output while maintaining a compact form factor suitable for electric two-wheelers. A further objective is to optimize the liquid cooling process by dynamically adjusting the coolant flow rates based on real-time sensor data. This ensures that the motor operates at optimal temperatures, thereby improving its durability and performance.

[0025] In one embodiment, the advanced wheel hub motor system for electric two-wheelers integrates a magnetless reluctance motor (SRM), a compact planetary gearbox, and an AI-controlled liquid cooling mechanism. The system consists of a wheel hub motor assembly with an integrated SRM, which operates with variable three-phase voltage and current, enabling precise control of speed and torque. The rotor position is detected via encoders or resolvers and fed back to a control unit, which regulates current, speed, and torque. Power electronics, consisting of IGBTs or MOSFETs driven by high-power gate signals, control the power supply to the stator windings, while intermediate circuit capacitors and a bidirectional DC / DC buck / boost converter stabilize and regulate the energy flow between the battery, supercapacitors, and motor.The planetary gearbox is seamlessly integrated into the motor housing and comprises components such as a carrier plate, ring gear, planet gears, and a sun gear, which are directly connected to the SRM rotor. This configuration significantly improves torque and acceleration at low speeds without increasing the motor's size. Bearings ensure precise alignment and smooth rotation, while the hollow shaft supports electrical and cooling connections. The wheel and tire assembly is mounted directly to the motor housing hub, creating a compact, road-ready structure. The AI-controlled liquid cooling system uses temperature data from integrated sensors to dynamically regulate coolant flow through the coil-shaped cooling tubes in the stator. An additional HVAC cooling unit, valves, pumps, and dedicated coolant lines maintain optimal operating temperatures, ensuring consistent performance even under heavy load conditions.The system is configured for AI-based predictive maintenance, where real-time engine condition data is transmitted via IoT to a cloud-based platform. There, AI algorithms analyze performance trends, detect potential faults, and notify the user before critical failures occur. This functionality minimizes downtime and extends system lifespan. The system also includes an AI-controlled automatic gear-shifting mechanism with selectable ECO, NORMAL, and SPORT modes. Based on real-time sensor data and driver input, the AI ​​adjusts gear ratios via a planetary gear set and an electrically actuated clutch, optimizing efficiency and performance under all driving conditions. Torque and speed are continuously optimized by the AI-based control system, which compares real-time data with target parameters to ensure operation within safe and efficient limits.In the event of a detected fault, the system can warn the rider, adjust performance parameters, or initiate an emergency shutdown to protect the motor and ensure safety. The invention offers a fully integrated, intelligent, and compact wheel hub motor solution that combines magnetless SRM technology, an advanced planetary gearbox, AI-controlled liquid cooling, predictive maintenance, and adaptive control. The proposed design provides superior thermal performance, torque delivery, and operational efficiency while enabling improved safety, reliability, and user-centric features for electric two-wheeled vehicles.

[0026] Fig. Figure 1 shows a diagram illustrating the magnetless SRM in a wheel hub motor with integrated planetary gear and liquid cooling according to an embodiment of the present disclosure.

[0027] In Fig. Figure 1 shows a magnetless SRM in a wheel hub motor with integrated planetary gearbox and liquid cooling. The system consists of several key components, each of which performs a crucial function in ensuring efficient performance and reliability of the motor assembly.

[0028] With reference to Fig. 1. The multitude of components and their functionality are described as follows: The electromagnetic / hydraulic brake actuator (100) is configured to actuate the disc brakes and provide the required force. Depending on the design, this actuator can be electromagnetic or hydraulic. It is mounted next to the disc brake plate (101) and connected to the brake system control unit.

[0029] The disc brake plate (101) provides the friction surface required for braking by clamping the disc and thus slowing down or stopping the wheel when the brake actuator (100) engages. It is attached to the hub of the motor housing (113) and positioned to interact with the brake actuator.

[0030] The retaining plate for the brake disc (102), attached to the motor housing, secures the brake disc (101) to the hub of the motor housing (113) and ensures stable mounting and correct alignment. It is attached to the hub of the motor housing (113).

[0031] The carrier plate of the planetary gear (103) supports and holds the planetary gear components within the motor assembly and ensures alignment and stability. It is mounted in the motor housing and aligns the sun gear (106), the planet gears (105) and the ring gear (104).

[0032] The ring gear (104) works together with the planet gears (105) to transmit the torque from the motor to the wheel hub, thus enabling smooth power transmission. It surrounds the planet gears (105) and is connected to the motor housing hub (113).

[0033] The planet gear (105) rotates around the sun gear (106) and transmits the rotational force to the ring gear (104). It is mounted on the carrier plate (103) of the planetary gear and engages with both the sun gear and the ring gear.

[0034] The sun gear (106) is the central gear of the planetary gear set and is driven directly by the rotor (108). It is mounted on the rotor shaft and is located centrally within the planetary gear set.

[0035] The inner bearing (107) supports the rotor (108) and ensures smooth rotation within the motor assembly. It is located between the rotor and stator (109) on the inside of the motor assembly.

[0036] The magnetless rotor (108) generates a rotational movement when excited by the stator (109), without the need for magnets. This increases the service life and reduces material costs. It is centrally located in the stator and connected to the sun gear (106).

[0037] The stator (109) contains three-phase concentrated copper windings that generate a rotating magnetic field and drive the rotor (108). It surrounds the rotor and is supported by the hollow shaft (112).

[0038] The liquid cooling coil tube (110) circulates liquid coolant to dissipate heat from the stator (109) and maintain optimal operating temperatures for consistent performance. It is wound around the stator, with connecting valves leading through the hollow shaft (112) to an external cooling system.

[0039] The outer bearing (111) provides additional support for the motor housing hub (113) and ensures smooth rotation of the wheel assembly. It is located on the outside of the motor assembly and supports the motor housing hub.

[0040] The hollow shaft (112) supports the stator (109) and allows for the routing of electrical connections and cooling tubes, thus ensuring integration with external systems. It is centrally located, runs through the stator, and establishes the connection to external systems.

[0041] The motor housing hub (113) encloses and protects the entire motor assembly from environmental influences and forms the structural basis for the wheel assembly. It encloses the motor assembly and the planetary gear set on which the tire and rim are mounted.

[0042] The rim (114) is the structural element on which the tire (115) is mounted and forms the outer edge of the wheel assembly. It is mounted on the hub of the motor housing (113).

[0043] The tire (115) touches the road surface and provides traction and damping for the vehicle. It is mounted on the rim (114) and encloses the entire wheel assembly.

[0044] Fig. Figure 2 shows an architecture diagram of the bidirectional motor control unit with integrated battery charge controller according to an embodiment of the present disclosure.

[0045] Referring to Fig. 2. The bidirectional motor controller with integrated battery charging controller comprises a variety of components, as described below:

[0046] The reluctance motor (SRM) (200) receives variable three-phase voltage and current and thus controls its speed and torque. It is integrated into the wheel hub motor assembly.

[0047] The position sensor (201) detects the rotor position using encoders or resolvers and provides feedback to the controller for precise timing control. It is located within the motor assembly.

[0048] The current control circuit (202) monitors the current in the stator windings and adjusts the circuit to maintain the desired current levels for smooth operation. It is integrated into the control unit.

[0049] The controller unit (203) receives input signals for the desired speed and torque, processes them with a microcontroller or DSP, and manages the speed control loop. It serves as the central control unit for motor operation.

[0050] The gate driver (204) converts low-power control signals into high-power gate signals for the power electronics and implements PWM for voltage and current control. It acts as an interface between the control unit and the power electronics.

[0051] The power electronics (205) consist of switches such as IGBTs or MOSFETs that control the current flow to the stator windings based on gate driver signals. They are connected to the motor and the control system and form the power stage of the system.

[0052] The intermediate circuit capacitors (206) stabilize the input DC voltage, thus ensuring smooth operation of the motor and the power electronics. They are located within the power electronics.

[0053] The bidirectional DC-DC buck-boost converter (207) manages the conversion of voltage levels between the battery and the motor controller and supports bidirectional power flow. It is integrated into the motor controller.

[0054] The supercapacitors (SC) (208) enable rapid energy storage and hybrid power supply for the inverter. They reduce the battery load during peak loads and renewable energy operation. They are connected in parallel to the battery.

[0055] The battery (209) supplies the necessary energy for motor operation and is controlled by the bidirectional DC-DC converter and charge controller. It is located in the vehicle's electrical system.

[0056] Fig. Figure 3 shows a block diagram of an automatic gearshift mechanism according to an embodiment of the present disclosure.

[0057] With reference to Fig. 3. The automatic gearshift mechanism comprises a variety of components, as described below: The switched reluctance wheel hub motor (SRM) (300) receives variable three-phase voltage and current to control speed and torque, which is essential for the dynamic operation of the vehicle. It is integrated into the wheel hub motor assembly.

[0058] A component configured for sensor-based data acquisition and pre-analysis (301) collects data from various sensors and performs pre-analysis to provide input to the controller. It is distributed throughout the engine and transmission system.

[0059] The shift mode switch (302) allows the driver to select between ECO, NORMAL, and SPORT modes, thus influencing the shifting behavior. It is easily accessible to the driver and is usually located on the dashboard or steering wheel.

[0060] The gear selector (303) engages the appropriate gear based on the selected mode and real-time sensor data. It is integrated into the automatic gearshift mechanism.

[0061] The brake switch (304) detects when the brake is applied and provides important information to the AI-based controller to adjust gear changes accordingly. It is connected to the braking system.

[0062] The AI-based controller for Eco, Normal, and Sport modes (305) receives input from driver switches and sensors (such as oil temperature, current gear position, and vehicle speed) and processes this data to provide the necessary PWM signals. These signals control various actuators, thus enabling automatic gear changes with an electrically operated clutch. The controller is centralized within the control unit and connected to all relevant system components.

[0063] The combined motor housing (306) encloses and protects the motor and its associated components, thus ensuring their integrity and optimal operation. It encloses the SRM and gearbox system.

[0064] The planetary gear set (307) dynamically adjusts the gear ratio to the selected driving mode, thus ensuring optimal performance and efficiency. It is integrated into the wheel hub motor system.

[0065] The electrically actuated clutch with automatic gear-shifting mechanism (308) enables seamless gear changes by automatically engaging and disengaging the gears, controlled by the AI-based system. It is connected to the planetary gear set and the AI ​​controller.

[0066] Fig. Figure 4 shows a block diagram of an AI-based enhanced liquid cooling system according to an embodiment of the present disclosure.

[0067] With reference to Fig. 4. The system is an integrated AI-based enhanced liquid cooling mechanism, the mechanism comprising a variety of components as described below: The switched reluctance wheel hub motor (SRM) (400) receives variable three-phase voltage and current to control speed and torque and requires effective cooling to prevent overheating. It serves as a central component of the cooling system.

[0068] The data acquisition and analysis component performs sensor-based data acquisition and pre-data analysis (401). The component acquires real-time data on temperature and other parameters and delivers this data to the AI-based cooling controller. It is integrated into the engine and cooling system.

[0069] The gate driver and isolation circuit (402) provides the necessary isolation and gate driver signals for the inverter module, thus ensuring safe and efficient motor operation. It is connected between the inverter and the motor.

[0070] The electric battery (403) supplies power to the engine and cooling system, which is essential for continuous operation. It is integrated into the vehicle's electrical system.

[0071] The inverter module (404) converts direct current from the battery into alternating current, which is required by the SRM. The output is regulated according to cooling requirements. It is located near the motor, thus ensuring efficient power delivery.

[0072] The artificial intelligence-based liquid cooling controller (405) analyzes temperature data and adjusts the operation of the cooling system to maintain optimal engine temperatures. It acts as a central control unit within the cooling system.

[0073] The HVAC cooling system (406) provides additional cooling support, particularly under high-load conditions, through its integration into the liquid cooling system. It is connected to the liquid cooling system and the engine.

[0074] The operating valve (407) regulates the coolant flow through the system and is controlled by the AI-based cooling controller. It is integrated into the cooling pipe network.

[0075] The coolant circulation pump (408) circulates the coolant through the engine and cooling system, thus ensuring consistent temperature management. It is connected to the coolant lines and the radiator.

[0076] The coolant pipe (409) returns the cooled fluid to the engine assembly, thus completing the cooling circuit. It runs through the entire cooling system.

[0077] The hot-liquid cooling pipe (410) carries the heated coolant from the engine to the radiator, which is essential for maintaining temperature balance. It is integrated into the engine and cooling system.

[0078] In one implementation, the system utilizes a variety of sensors for data acquisition. These sensors are externally mounted on each engine and capture real-time engine performance data, including temperature, speed, and vibration. Wireless cloud storage stores the collected data in the cloud, enabling remote access and analysis. It is cloud-based and accessible via the internet. The system is configured for data processing using novel AI-based algorithms that analyze the collected data to identify patterns, predict performance, and pinpoint potential problems. This processing can occur in the cloud or within the vehicle's onboard system. The system is also configured for fault detection and diagnosis. It identifies and diagnoses faults in the engine and vehicle systems and triggers necessary warnings and corrective actions.It is integrated into the AI-based data processing system. The vehicle's real-world operating dataset for various conditions is provided as ideal data for training the model. This dataset uses real-world data to train AI models, ensuring accurate performance predictions and fault detection. It is cloud-based and used for model training and validation. The mathematically and digitally tuned model for engine and electric vehicle simulation simulates engine and vehicle performance under various conditions and provides a benchmark for real-time data comparison. It is part of the digital twin and the AI ​​processing system. The system is configured to perform data analysis by comparing it to ideal model simulation results. It compares real-time data with simulated results to evaluate performance and identify deviations.It is either cloud-based or integrated into the vehicle's onboard processing system. The system features an automatic fault warning display that provides protection through rapid maintenance. Upon detecting faults, the system issues immediate warnings and maintenance recommendations, thus increasing safety and reliability. The warning display is integrated into the vehicle's dashboard and user interface. The system is configured to allow user devices to access the data. An electric vehicle fault diagnostic app or website enables users to access real-time data and diagnostics, facilitating proactive maintenance and monitoring. Access is via mobile devices or computers connected to the cloud storage and data analysis system.

[0079] During implementation, the system is configured to optimally adjust torque and speed for improved efficiency, thereby increasing range by reducing battery consumption. The system first initializes safe reference parameters for the motor, establishing values ​​such as temperature, speed, vibration, current, and voltage to create a baseline for monitoring using the controller. Once the baseline is established, the system collects sensor data and transmits it to the IoT database or cloud storage, enabling remote access and further analysis. Using this collected data, the system continuously monitors all motor parameters on the IoT platform, ensuring uninterrupted real-time tracking of conditions.The motor's performance is then checked by comparing the actual values ​​with target values, such as temperature and speed, to ensure operation remains within the optimal range. Based on this assessment, the system sends commands to the controller, the VFD drive, and the battery management system (BMS), making adjustments to ensure stable and efficient operation of both the motor and the battery. During monitoring, the system uses an AI-based control tool to check for faults, analyzes operating data to identify anomalies, provides precise diagnoses, and suggests corrective actions. If a problem is detected, the system displays a warning message on the vehicle's screen or a mobile device to inform the driver in real time.In the event of a critical fault, the system can immediately shut down the engine by switching it off or locking it, thus preventing potential damage or accidents. If no serious problems are detected, the engine continues to run while all parameters are monitored and controlled to ensure that torque and speed remain optimized for maximum efficiency. This continuous adjustment helps to improve the vehicle's range while reducing unnecessary battery consumption.

[0080] The present invention relates to an advanced wheel hub motor system for electric two-wheelers, which combines a magnetless reluctance motor (SRM) with an innovative planetary gearbox and an AI-controlled liquid cooling mechanism. The proposed integrated system design addresses the critical challenges of thermal management, torque delivery, and operational efficiency in compact electric vehicle drive systems. By combining mechanical, electrical, and intelligent control innovations in a single hub assembly, the invention achieves improved performance, reliability, and durability compared to conventional hub motor architectures.

[0081] In one embodiment, the hub motor uses a magnetless SRM configuration to reduce reliance on rare-earth magnets, thereby lowering manufacturing costs and mitigating the environmental concerns associated with magnet production. The SRM is housed within the wheel hub, with the planetary gearbox seamlessly integrated into the motor housing. The gearbox is designed to multiply torque at low speeds, thus improving acceleration and climbing ability without compromising compactness or weight distribution. This integration ensures minimal power transmission losses while maintaining high mechanical efficiency.

[0082] In one embodiment, the system also features an AI-controlled liquid cooling system that dynamically adjusts coolant flow rates. Data is acquired in real time by strategically placed temperature sensors within the motor assembly. This intelligent cooling approach ensures optimal operating temperatures under varying load conditions, effectively prevents overheating, and improves both motor performance and lifespan. The cooling system is fully integrated into the hub motor assembly, maintaining a compact design and protecting the components from external environmental influences.

[0083] In one embodiment, the system uses an AI control module to monitor and adjust motor parameters such as torque, speed, and temperature in real time. By processing sensor-based data, the AI ​​system continuously optimizes energy consumption and adapts motor operation to varying terrain, load, and driving conditions. This results in improved energy efficiency, particularly at low torque, thus increasing the electric vehicle's range without compromising performance.

[0084] In one embodiment, the system utilizes IoT-based connectivity and wireless cloud integration for predictive maintenance and performance monitoring. Sensor data on motor temperature, speed, vibration, and torque are transmitted to a secure cloud platform, where AI algorithms analyze trends to detect early signs of wear or component failure. This predictive diagnostic capability enables timely maintenance interventions, reduces downtime, and minimizes the risk of unexpected failures. The system is accessed via a user-friendly interface available through mobile applications or web platforms, allowing users to monitor performance metrics, receive error messages, and conveniently schedule maintenance activities.

[0085] The system is configured to deliver a highly efficient, durable, and intelligent wheel hub motor system specifically tailored for electric two-wheelers. The integration of a planetary gear into the SRM assembly increases torque while maintaining a compact design, AI-controlled liquid cooling ensures thermal stability, and IoT-supported predictive maintenance extends the service life. The present invention offers a comprehensive solution for overcoming the limitations of existing wheel hub motor systems for electric vehicles.

[0086] Fig. Figure 5 shows a block diagram of an integrated wheel hub motor system with AI-controlled control system (500) and advanced cooling mechanism according to an embodiment of the present disclosure.

[0087] Referring to Fig.5 The system (500) comprises: a magnetless switched reluctance motor (SRM) (502) with a stator having three-phase concentrated copper windings and a magnetless rotor, wherein the motor (502) can be operated with variable three-phase voltage and current; a planetary gearbox (504) integrated into a motor housing hub (502a) comprising: a sun gear directly coupled to the SRM rotor, several planet gears, a ring gear, and a carrier plate holding the planetary gearbox, wherein the motor housing hub (502a) is configured to enclose the magnetless switched reluctance motor (502) and the planetary gearbox (504) and to support the mounting of a rim and tire assembly; a liquid cooling system (506) comprising liquid-cooled, serpentine tubes positioned around the stator and circulating liquid coolant for thermal regulation;multiple sensors (508) that monitor engine temperature, speed, torque, and vibration in real time; an AI-based control module (510) configured to: receive real-time data from the multiple sensors (508); dynamically adjust engine parameters such as torque, speed, and thermal management based on the received data; optimize energy consumption by adapting engine operation to varying terrain, load, and driving conditions; and control the coolant flow rates of the liquid cooling system based on engine temperature, speed, and load; and an IoT connectivity module (512) configured to transmit sensor data to a cloud-based platform (514) for predictive maintenance and performance tracking.

[0088] In one embodiment, the stator and the magnetless rotor are made of laminated silicon steel, with the hub of the motor housing being configured to provide protection against environmental influences such as dust, dirt and moisture.

[0089] In one embodiment, the planetary gear (504) further comprises: an inner bearing that supports the magnetless rotor and ensures smooth rotation within a motor assembly; an outer bearing that supports the motor housing hub and ensures smooth rotation of a wheel assembly; and a hollow shaft that supports the stator and facilitates the passage of electrical connections and cooling tubes.

[0090] In one embodiment, the AI-based control module (510) is also configured to: analyze engine condition data to identify potential faults; perform predictive maintenance by detecting early signs of wear or component failure; and generate warnings via a connected interface before critical faults occur.

[0091] In one embodiment, the liquid cooling system (506) further comprises: temperature sensors strategically placed in the engine assembly; coolant pumps configured to circulate liquid coolant through the liquid cooling coil-like tubes; coolant valves configured to regulate the coolant flow; and an additional HVAC cooling unit (506a) configured to maintain optimal operating temperatures by providing additional cooling support, particularly under high-load conditions, wherein the HVAC cooling unit (506a) is integrated into the liquid cooling system (506).

[0092] In one embodiment, the system (100) further comprises a bidirectional motor control unit (516) with an AI-controlled automatic gearshift mechanism (518), wherein the motor control unit (516) comprises: power electronics including IGBTs or MOSFETs configured to manage the power supply to the stator windings based on gate driver signals; DC link capacitors configured to stabilize the energy flow; a bidirectional DC-DC buck / boost converter configured to control the energy flow between a battery, supercapacitors, and the motor;and encoders or resolvers configured to detect the rotor position and provide feedback for closed-loop control, wherein the bidirectional motor control unit is integrated with a battery charge controller, and a battery configured to provide the necessary power for motor operation, managed by the bidirectional DC-DC converter and charge controller.

[0093] In one embodiment, the AI-controlled automatic gearshift mechanism (518) is configured to adjust the gear ratios via the planetary gear set, the selectable driving modes including ECO, NORMAL and SPORT modes, and an electrically actuated clutch is configured to optimize efficiency and performance under all driving conditions.

[0094] In one embodiment, the cloud-based platform (514) is configured to: receive and store sensor data from the IoT connectivity module (512); execute AI algorithms to analyze performance trends; detect potential faults based on the analyzed trends; and provide a user interface accessible via mobile applications or web platforms for monitoring performance metrics and planning maintenance activities.

[0095] In one embodiment, the system (100) further comprises: a disc brake plate (520) mounted on the motor housing hub (502a); an electromagnetic or hydraulic brake actuator (522) configured to engage with the disc brake plate (520); and a brake plate (524) connecting a retaining plate configured to secure the disc brake plate (520) to the motor housing hub (502a).

[0096] In one embodiment, the AI-based control module (510) is also configured to compare real-time sensor data with predefined target parameters, to ensure engine operation within safe and efficient limits, to issue warnings to the driver upon detection of faults, to adjust performance parameters in response to detected faults, and to initiate emergency shutdown procedures to protect the engine and ensure safety.

[0097] The present invention relates to an advanced wheel hub motor system that overcomes the challenges of conventional designs by integrating artificial intelligence (AI) for dynamic motor control. The system continuously monitors and controls torque, speed, and cooling in real time, thereby improving energy efficiency and overall performance. The system is configured for sensor-based data acquisition, with multiple sensors continuously monitoring temperature, speed, vibration, and other parameters. The acquired data is processed by AI algorithms to dynamically optimize motor functionality—a feature lacking in existing systems. In addition to performance optimization, the system utilizes AI-driven fault diagnosis for the early detection of potential problems. This predictive maintenance function enables timely warnings and maintenance planning, prevents unexpected failures, and extends the motor's service life.Energy efficiency is further enhanced by AI's ability to adapt motor operation to varying load and torque requirements, minimizing power consumption at low torque and reducing battery discharge. The system also ensures seamless connectivity via IoT platforms, allowing users to remotely monitor motor performance, receive error messages, and schedule maintenance through mobile or web interfaces. Mechanically, the motor integrates a planetary gearbox into its housing, improving torque delivery while maintaining a compact design optimized for two-wheeled applications. The system also incorporates an AI-optimized liquid cooling system that dynamically regulates coolant flow rates based on real-time data, ensuring consistent thermal management under varying conditions.

[0098] The present invention provides a magnetless, switched reluctance motor (SRM) system in wheel hubs, featuring an integrated planetary gearbox and liquid cooling. AI algorithms dynamically control torque, speed, and thermal management in real time based on sensor data to optimize performance and energy efficiency. The motor incorporates an integrated planetary gearbox and advanced liquid cooling within the housing. This reduces size and weight for two-wheel applications without compromising efficiency. The stator and rotor construction consists of laminated silicon steel, enhancing durability, efficiency, and reliability. The protective housing shields against dust, dirt, and moisture. The system also includes AI-based predictive maintenance. By analyzing condition data, faults are detected early, and users are alerted to critical failures, thereby reducing downtime.The AI-controlled liquid cooling system adjusts coolant flow rates based on engine temperature, speed, and load to prevent overheating and ensure stable performance. The integrated planetary gear system delivers improved low-end torque, enhancing acceleration and overall vehicle performance while minimizing complexity. Finally, IoT-enabled real-time monitoring ensures that engine data is analyzed on AI-powered cloud platforms, providing users with continuous monitoring, fault detection, and performance optimization.

[0099] The drawings and the preceding description show examples of embodiments. Those skilled in the art will recognize that one or more of the described elements can be combined to form a single functional element. Alternatively, certain elements can be divided into several functional elements. Elements of one embodiment can be added to another embodiment. For example, the sequence of the processes described here can be changed and is not limited to the manner described here. Furthermore, the actions of a flowchart need not be implemented in the sequence shown; nor does it necessarily have to be performed by all actions. Actions that are not dependent on other actions can also be performed in parallel with the other actions. The scope of the embodiments is in no way limited by these specific examples.Numerous variations are possible, whether explicitly stated in the specification or not, such as differences in structure, dimensions, and material use. The range of embodiments is at least as broad as specified in the following claims.

[0100] Advantages, further benefits, and problem solutions have been described above with reference to specific embodiments. However, the advantages, benefits, problem solutions, and all components that can lead to an advantage, benefit, or solution occurring or becoming more apparent are not to be construed as critical, necessary, or essential features or components of individual or all claims. REFERENCE 100 The electromagnetic / hydraulic brake actuator is configured to actuate the disc brakes by providing the required force. 210 Hybrid energy storage system consisting of lithium-ion battery and supercapacitor 212 Ubus 214 Drive signal 216 Control signal 302 PWM solenoid valve 1 304 PWM solenoid valve 2 306 Five on / off valves 308 Oil temperature 310 Current Equipment 312 Vehicle speed 502 Magnetless Switched Reluctance Motor (SRM) 502a Engine housing hub 504 planetary gear 506 Liquid cooling system 506a Additional HVAC cooling unit 508 Variety of Sensors 510 AI-based control module 512 IoT connectivity module 514 Cloud-based platform 516 Bidirectional motor control unit 518 AI-controlled automatic gear shifting mechanism 520 disc brake plate 522 Electromagnetic or Hydraulic Brake Actuator 524 Brake plate

Claims

[1] An integrated wheel hub motor system with AI-controlled control system and advanced cooling mechanism, consisting of: a magnetless switched reluctance motor (SRM) comprising a stator with three-phase concentrated copper windings and a magnetless rotor, wherein the motor can be operated with variable three-phase voltage and current; a planetary gearbox integrated into a motor housing hub comprising: a sun gear directly coupled to the SRM rotor, several planet gears, a ring gear and a carrier plate for mounting the planetary gearbox, the motor housing hub being configured to enclose the magnetless switched reluctance motor and the planetary gearbox and to support the mounting of a rim and tire assembly; a liquid cooling system comprising liquid-cooling, serpentine tubes arranged around the stator and configured to circulate liquid coolant for heat regulation; a large number of sensors configured to monitor engine temperature, speed, torque and vibration in real time; an AI-based control module configured to: receive real-time data from a variety of sensors; dynamically adjust engine parameters such as torque, speed, and thermal management based on the received data; optimize energy consumption by adapting engine operation to varying terrain, load, and driving conditions; and control the coolant flow rates of the liquid cooling system based on engine temperature, speed, and load; and an IoT connectivity module configured to transmit sensor data to a cloud-based platform for predictive maintenance and performance tracking. [2] System according to claim 1, wherein the stator and the magnetless rotor are made of laminated silicon steel, wherein the hub of the motor housing is configured to provide protection against environmental influences such as dust, dirt and moisture. [3] System according to claim 1, wherein the planetary gear further comprises: an inner bearing configured to support the magnetless rotor and ensure smooth rotation within a motor assembly; an outer bearing configured to support the motor housing hub and ensure smooth rotation of a wheel assembly; and a hollow shaft configured to support the stator and facilitate the passage of electrical connections and cooling tubes. [4] System according to claim 1, wherein the AI-based control module is further configured to analyze engine condition data to identify potential faults; to perform predictive maintenance by detecting early signs of wear or component failure; and to generate warnings via a connected interface before critical faults occur. [5] System according to claim 1, wherein the liquid cooling system further comprises: temperature sensors strategically placed in the engine assembly; coolant pumps configured to circulate liquid coolant through the liquid cooling coil-like tubes; coolant valves configured to regulate the coolant flow; and an additional HVAC cooling unit configured to maintain optimal operating temperatures by providing additional cooling support, particularly under high-load conditions, wherein the HVAC cooling unit is integrated into the liquid cooling system. [6] System according to claim 1, further comprising a bidirectional motor control unit with an AI-controlled automatic gearshift mechanism, wherein the motor control unit comprises: power electronics including IGBTs or MOSFETs configured to manage the power supply to the stator windings based on gate driver signals; DC link capacitors configured to stabilize the energy flow; a bidirectional DC-DC buck / boost converter configured to regulate the energy flow between a battery, supercapacitors and the motor;and encoders or resolvers configured to detect the rotor position and provide feedback for closed-loop control, wherein the bidirectional motor control unit is integrated with a battery charge controller, and a battery configured to provide the necessary power for motor operation, managed by the bidirectional DC-DC converter and charge controller. [7] System according to claim 6, wherein the AI-controlled automatic gearshift mechanism is configured to adjust the gear ratios via the planetary gear set, wherein the selectable driving modes include ECO, NORMAL and SPORT modes, and wherein an electrically actuated clutch is configured to optimize efficiency and performance under all driving conditions. [8] System according to claim 1, wherein the cloud-based platform is configured to: receive and store sensor data from the IoT connectivity module; execute AI algorithms to analyze performance trends; detect potential faults based on the analyzed trends; and provide a user interface accessible via mobile applications or web platforms for monitoring performance metrics and planning maintenance activities. [9] System according to claim 1, further comprising: a disc brake plate mounted on the hub of the motor housing; an electromagnetic or hydraulic brake actuator configured to engage the disc brake plate; and a retaining plate for connecting the brake plate, configured to fasten the disc brake plate to the hub of the motor housing. [10] System according to claim 1, wherein the AI-based control module is further configured to compare real-time sensor data with predefined target parameters, to ensure engine operation within safe and efficient limits, to issue warnings to the driver upon detection of faults, to adjust performance parameters in response to detected faults, and to initiate emergency shutdown procedures to protect the engine and ensure safety.

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