A motor for a vehicle

Abstract

The present disclosure provides a motor (200) for a vehicle (100) The motor (200) comprises a motor shaft (204), a magnet (206) positioned at a rear end of the motor shaft (204), an encoder (208) disposed at a predefined distance from the magnet (204), a front bearing (210) disposed around a front end of the motor shaft (204), a rear bearing (212) bearing disposed around a rear end of the motor shaft (204), at least one stopper (302) adapted to attach the front bearing (210) to a housing (202) of the motor (200); and a front gear (214) disposed above the motor shaft (204) and in front of the front bearing (210).

Description

TITLE OF THE INVENTION:A MOTOR FOR A VEHICLETECHNICAL FIELD

[0001] The present subject matter generally relates to automotive industry. More particularly, but not exclusively to, a motor for a vehicle.BACKGROUND

[0002] Technical advancements in the field of the automotive industry have led to significant improvements in efficiency, performance, and reliability of modern motor systems. A key development in the motor has been an integration of precise feedback control systems, such as encoders, which are used to monitor positions and movements of components within electric motors and other mechanical systems. Such advancements have enabled more accurate control of motor commutation, leading to better overall motor performance, reduced energy consumption, and enhanced user experience.

[0003] However, with the growing complexity of automotive systems, new challenges have emerged, particularly concerning the accuracy of encoder readings. Encoders rely on a stable and consistent distance between the encoder and a corresponding magnet attached to a rotor shaft of the motor. Variations in the distance, caused by factors such as axial movement of the shaft, thermal expansion, and manufacturing tolerances, can lead to inconsistent encoder readings, which in turn disrupt the motor’s performance and efficiency. Such variations in the distance, even if minute, can lead to significant consequences, including poor phase commutation, motor malfunctions, increased wear and tear, reduced motor lifespan, and increased noise and vibration.

[0004] In order to mitigate the aforesaid issues, traditional motors have focused on improving mechanical tolerances and using standard components like bearings and shaft collars to minimize axial movement. While effective to some extent, such motors have proven insufficient in addressing a full range of potential variables, such as thermal expansion or the continuous axial forces that arise during motor operation.

[0005] Thus, there is a need in the art for a motor, which addresses at least the aforementioned problems and other problems of known art.SUMMARY OF THE DISCLOSURE

[0006] According to embodiments illustrated herein, the present disclosure relates to motor that compensates for variations in distance between an encoder and a magnet, ensuring more precise operation and extending the lifespan of motor systems in automotive applications and beyond.

[0007] In an aspect, the present disclosure relates to a motor for a vehicle. The motor comprises a motor shaft, a magnet positioned at a rear end of the motor shaft, an encoder disposed at a predefined distance from the magnet, a front bearing disposed around a front end of the motor shaft, a rear bearing disposed around a rear end of the motor shaft, at least one stopper adapted to attach the front bearing to a housing of the motor, and a front gear disposed above the motor shaft and in front of the front bearing.

[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The details are described with reference to an embodiment of a vehicle along with the accompanying diagrams. The same numbers are used throughout the drawings to reference similar features and components.

[0010] Figure 1 illustrates a side view of a vehicle, in accordance with an embodiment of the present subject matter.

[0011] Figure 2A exemplarily illustrates a sectional view of a motor of the vehicle of Figure 1, in accordance with an embodiment of the present disclosure.

[0012] Figure 2B exemplarily illustrates a detailed view of an encoder side of the motor of Figure 2 A, in accordance with an embodiment of the present disclosure.

[0013] Figure 3 exemplarily illustrates a front view of a shaft stopper, in accordance with an embodiment of the present disclosure.

[0014] Figure 4 exemplarily illustrates a side view of the shaft stopper of Figure 3, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0015] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosedprinciples are described herein, modifications, adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope and spirit being indicated by the following claims.

[0016] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the disclosure(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.

[0017] The embodiments of the present disclosure will now be described in detail with reference to a vehicle with the accompanying drawings. However, the present disclosure is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0018] Figure. 1 illustrates a side view of a vehicle (100) in accordance with an embodiment of the present invention. The vehicle (100) includes a frame assembly (not shown) to support different parts of the vehicle (100). In an upper portion of the frame assembly (not shown), a handlebar assembly (115) is rotatably integrally connected to the steering shaft (not shown). The handlebar assembly (115) is used to steer the vehicle (100) and is connected to a front wheel (185) through the steering shaft (not shown) and a front fork assembly (not shown). An upper portion of the front wheel (185) is covered by a front fender (190) which prevents mud and water from getting deflected towards the steering shaft (not shown). Further, the front fork assembly (195) is supported on the front fender (190) by means of a brace fender (not shown).

[0019] In a front portion of the frame assembly (not shown) a fuel tank assembly (120) is arranged immediately behind the handlebar assembly (115) and is disposed over a first power source, for example an internal combustion engine (180). A seat assembly (125) is placed behind the fuel tank assembly (120). The seat assembly (125) includes a front rider seating portion and a pillion rider seating portion. The pillion rider seating portion is placed on the rear part of the frame assembly (not shown), where the rear part of the frame assembly (not shown) is covered by the tail cover assembly (not labelled).

[0020] For the safety of the rider and in conformance with the traffic rules, a headlamp assembly (105) that includes a headlamp (110) and front indicator lights (140a) are provided in the front portion of the vehicle (100). On the rear portion of the two wheeled vehicle (100) a tail lamp (not labeled) and rear indicator light (140b) are provided on the rear portion of the tail cover assembly (not shown). Above a tail cover assembly (130) and behind the seat assembly (125) a pillion handle (135) is provided for the pillion rider to grab.

[0021] Suspension systems are provided for comfortable steering of the two wheeled vehicle (100) on the road. A front suspension assembly (195) serves as rigidity component for the front portion of the vehicle (100) just like the frame assembly (not shown). The front suspension assembly (195) clamped to the head tube (not shown) through an upper bracket (not labelled) and a lower bracket (not labelled) is capable of being moved to the left and right. Further, a rear suspension system (160), which is a hydraulic damped arrangement, is connected to the frame assembly (not shown). The rear suspension system (160) comprises of at least one rear suspension (160) preferably disposed centrally in the longitudinal mid plane of the vehicle (100). However, in a vehicle (100) with two rear suspensions, the same may be disposed on the left side and the right side respectively of the vehicle (100).

[0022] The first power source, for example the internal combustion engine (180) is mounted to a front lower portion of the frame assembly (not shown) by means of an engine mounting bracket (not shown). The internal combustion engine (180) is partially covered on the lower side of the internal combustion engine (180) by an engine cover (175). The internal combustion engine (180) is equipped with an exhaust system that includes an exhaust pipe connected to the internal combustion engine(180) and a muffler assembly (155) connected to the exhaust pipe. The muffler assembly (155) extends rearwards along the right side of the rear wheel (150).

[0023] Further, a swing arm (191) extending rearwards is swingably connected to a lower rear portion of the vehicle (100). The rear wheel (150) is rotatably supported at a rear end of the swing arm (191). Power from the internal combustion engine (180) is transmitted to the rear wheel (150) through a power drive mechanism, such as a drive chain, so as to drive and rotate the rear wheel (150). A centre stand (165) is provided in between the front wheel (185) and the rear wheel (150) for parking the vehicle (100).

[0024] A rear fender (145) for covering an upper side of the rear wheel (150) is mounted to a rear portion of the vehicle (100) to prevent mud and water splashed by the rotating rear wheel (150) from entering the muffler assembly (155), the internal combustion engine (180) and other parts disposed close by. To enhance the overall aesthetics of the vehicle (100) and to prevent undesired foreign particles from entering parts of the vehicle (100), a plurality of rear covers (not labelled) is attached to a rear portion of the frame assembly (not shown).

[0025] Area below the seat assembly (125) and the fuel tank assembly (120) of the vehicle (100) is covered on both sides by a cover frame assembly (170). The cover frame assembly (170) includes the one or more side covers.

[0026] Figure 2A exemplarily illustrates a sectional view of a motor (200) of the vehicle (100) of Figure 1, in accordance with an embodiment of the present disclosure.Figure 2B exemplarily illustrates a detailed view of an encoder side of the motor (200) of Figure 2 A, in accordance with an embodiment of the present disclosure.

[0027] Referring to Figure 2A and 2B in conjunction. The motor (200) for the vehicle (100) comprises a motor shaft (204), a magnet (206) positioned at a rear end of the motor shaft (204), an encoder (208) disposed at a predefined distance from the magnet (204), a front bearing (210) disposed around a front end of the motor shaft (204), a rear bearing (212) bearing disposed around a rear end of the motor shaft (204), at least one stopper (302 of Figure 3) adapted to attach the front bearing (210) to a housing (202) of the motor (200), and a front gear (214) disposed above the motor shaft (204) and in front of the front bearing (210).

[0028] The motor (200) in a two-wheeler vehicle (such as, the vehicle 100) may be an internal combustion engine or electric motor that powers the vehicle (100) by converting energy into mechanical motion to propel the vehicle (100) forward. Typically, the motor (200) operates by burning fuel (in gasoline engines) or using electricity (in electric bikes) to generate power, which is transmitted to the wheels (150, 185) via a transmission system. The motor (200) may be a core component of the vehicle (100), providing a necessary force for movement and determining the vehicle's speed and performance.

[0029] The motor shaft (204) refers to a rotating component that transmits mechanical power from internal mechanisms of the motor (200) to other parts of the vehicle (100), such as the wheels (150, 185) or other drive components. In the twowheeler vehicle (100), the motor shaft (204) typically connects to a transmission system. The motor (200) convert’s rotational energy of the motor shaft (204) into a motion that drives the vehicle (100) forward. The motor shaft (204) rotates as the motor operates. Typically, in internal combustion engines, the motor shaft (204) is usually connected to a crankshaft.

[0030] The magnet (206) may be a key component that plays a crucial role in the functioning of the motor (200) (especially in permanent magnet motors). The magnet (206) may be used to create a magnetic field, which interacts with an armature (not shown) of the motor (200) to generate the motion. In permanent magnet motors, the magnet (206) may be fixed in a stator (i.e. a stationary part of the motor 200)), and as electricity flows through the coil (rotor), it creates a magnetic field. The interaction between a magnetic field of the stator and the rotor causes the rotor to turn, generating a rotational force needed to drive the vehicle (100).

[0031] The encoder (208) in the motor (200) may be a sensor that measures the rotation of the motor shaft (204) and provides feedback about a position, speed, and direction of the motor shaft (204). Encoders are commonly used in electric motors to ensure precise control of a motor operation.

[0032] The front bearing (210) in the motor (200) is a mechanical component that supports the motor shaft (204) of the motor (200). The front bearing (210) help in reducing friction between the rotating parts (like the motor shaft 204) and stationaryparts. Thus, the front bearing (210) enable smooth rotation and reducing wear and tear on components of the motor (200).

[0033] The rear bearing (212) of the motor (200) may be similar in function to the front bearing (210) but may be located at the rear of the motor (200), typically supporting an opposite end of the motor shaft (204). Just like the front bearing (210), the rear bearing (212) reduces friction between the motor shaft (204) and the stationary parts of the motor (200), ensuring smooth and efficient operation.

[0034] In an embodiment, the motor (200) comprises a spring (216) disposed at a rear of the rear bearing (212). In an embodiment, the spring (216) is a wave spring washer.

[0035] In an embodiment, predefined distance of the encoder (208) from the magnet (204) is 1.5 mm to 2 mm. It may be appreciated that the magnet (204) may have a north pole and a south pole. A magnetic field may be created when the motor shaft (204) rotates. The magnetic field may be read by the encoder (208) to determine a position and a rotation of the motor shaft (204). In order to do so, the predefined distance must be maintained between the encoder (208) and the magnet (204) so that the encoder (208) and the magnet (204) do not come in contact with each other. Furthermore, if the distance between the encoder (208) and the magnet (204) is greater than the predefined distance, then the magnetic field reaching the encoder (208) may be weaker to be read by the encoder (208).

[0036] In an embodiment, the front gear (214) is a helical gear. The helical gear may have an axial force. Further, when rotated, the helical gear may have an axial force that may be towards the magnet (206). Thus, the front gear (214) may ensure that the magnet (204) moves towards the encoder (208) and not away from it.

[0037] In an embodiment, a casting (220) is disposed around the motor shaft (204) within the housing (202), and the casting (220) is adapted to disable a movement of the front bearing (210) in a second direction (218B). The casting (220) may prevent the movement of the motor shaft (204) in a right direction. Thus, a touching of magnet (206) with the encoder (208) during operation may be prevented. In an embodiment, the front bearing (210) and the rear bearing (212) is loosely fitted to the motor shaft (204) to enable a free movement of the motor shaft (204). In an embodiment, the front gear (214) is fastened to the motor shaft (204) via one or more fastening mechanisms.

[0038] Figure 3 exemplarily illustrates a front view of a shaft stopper, in accordance with an embodiment of the present disclosure. Figure 4 exemplarily illustrates a side view of the shaft stopper of Figure 3, in accordance with an embodiment of the present disclosure. With reference to Figure 3 and Figure 4 in combination, in an embodiment, the at least one stopper (302) is adapted to disable a movement of the front bearing (210) in a first direction (218). In an embodiment, the at least one stopper (302) comprises a lock plate (302A) and a fastener (304) configured to fasten the front bearing (210) to the housing (202). The fastener (304) may be a bolt. The stopper (302) in the motor (200) may be a component that limits or restricts the movement of the front bearing (210) to prevent over-rotation or mechanical damage. Traditionally, the front bearing (210) and the rear bearing (212) are tight fitted with the motor shaft (204) and loose fitted with a housing (202). Thus, in such cases when the motor shaft (204) moves front and back, the front bearing (210) and the rear bearing (212) may also move. In order to mitigate the aforesaid problem, the disclosed motor (200) may comprise the at least stopper (302) that may be tight fitted to the housing (202). The at least one stopper (302) may arrest the movement of the front bearing (210) along with the motor shaft (204). In an example, a first lock plate is fastened to a first side of the front bearing (210) to the housing (202) and a second lock plate is fastened to a second side of the front bearing (210) to the housing (202). Herein, the first lock plate and the second lock plate are diagonally positioned.

[0039] Thus, in the disclosed motor a position of wave spring washer is rearranged closer to the encoder to resist axial forces towards an encoder side of the motor and to maintain consistent encoder-magnet distance. Further, shaft stoppers are provided on a transmission end of the motor shaft in order to preventing a movement of the front bearing towards the transmission side with respect to the housing. Therefore, the disclosed motor help in maintaining consistent encoder-magnet distance.

[0040] A description of an embodiment with several components in communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the disclosure.

[0041] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected todelineate or circumscribe the inventive subject matter and is therefore intended that the scope of the disclosure be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present disclosure are intended to be illustrative, but not limiting, of the scope of the disclosure, which is set forth in the following claims.

[0042] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0043] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.

Claims

WE CLAIM:

1. A motor (200) for a vehicle (100) comprising:a housing (202) that includesa motor shaft (204);a magnet (206) positioned at a rear end of the motor shaft (204); an encoder (208) disposed at a predefined distance from the magnet (204) towards the rear end of the motor shaft (204);a front bearing (210) disposed around a front end of the motor shaft (204);a rear bearing (212) bearing disposed around a rear end of the motor shaft (204);at least one stopper (302) coupled with the front bearing (210), the at least one stopper (302) attached to the housing (202) of the motor (200); and a front gear (214) disposed above the motor shaft (204) and in front of the front bearing (210).

2. The motor (200) as claimed in claim 1, wherein the at least stopper (302) comprises a lock plate (302A) and a fastener (304) configured to fasten the front bearing (210) to the housing (202).

3. The motor (200) as claimed in claim 1 comprising a spring (216) disposed at a rear of the rear bearing (212).

4. The motor (200) as claimed in claim 3, wherein the spring (216) is a wave spring washer.

5. The motor (200) as claimed in claim 1, wherein the front gear is a helical gear.

6. The motor (200) as claimed in claim 1, the predefined distance of the encoder (208) from the magnet (204) is in range of 1.5 millimetre (mm) to 2 millimetre (mm).

7. The motor (200) as claimed in claim 1, wherein the at least one stopper (302) is adapted to disable a movement of the front bearing (210) in a first direction (218 A).

8. The motor (200) as claimed in claim 7, comprisinga casting (220) is disposed around the motor shaft (204) within the housing (202), andthe casting (220) is adapted to disable a movement of the front bearing (210) in a second direction (218B).

9. The motor (200) as claimed in claim 1, wherein the front bearing (210) and the rear bearing (212) is loosely fitted to the motor shaft (204) to enable a free movement of the motor shaft (204).

10. The motor (200) as claimed in claim 1, wherein the front gear (214) is fastened to the motor shaft (204) via one or more fastening mechanisms.

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