Electric Conversion Assembly for Two-Wheeler Thermal Packaging
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Solution Overview
Problem
Existing conversion systems for converting internal combustion engine vehicles to electric vehicles are cumbersome, costly, and lack flexibility, often requiring complete overhaul, poor thermal management, and are not suitable for two-wheeled vehicles, leading to issues with weight, cost, and space constraints.
Innovation Solution
A conversion assembly for multi-wheeled vehicles that includes an electric machine connected to a transmission assembly, housed in a compact design with natural air cooling, allowing easy installation and flexibility to revert to IC power, featuring a lightweight and efficient design with improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional internal combustion engine is used, then vehicle can operate with simple fuel tank and engine setup, but harmful emissions are released into atmosphere and fuel cost is high
Solution Approach 1:
The conversion assembly is divided into separate modular components: electric machine, transmission assembly with gear train, and housing with cooling channels. This segmentation allows independent optimization of each component and simplifies the overall conversion process from IC engine to electric powertrain.
Solution Approach 2:
The transmission assembly serves multiple functions: it provides gear reduction for torque multiplication, incorporates natural air cooling through integrated cooling channels in the housing, and enables reversible conversion between IC and electric power modes. This multi-functionality reduces the need for separate cooling systems and simplifies the conversion design.
2Adaptability or versatility
If complete overhaul conversion system is used, then IC vehicle can be converted to electric vehicle, but conversion process is cumbersome and costly
Solution Approach 1:
The conversion assembly is pre-assembled as a complete unit including electric machine, transmission, and cooling system before installation on the vehicle. This preliminary preparation simplifies the actual conversion process to a straightforward replacement operation, reducing both time and cost while maintaining flexibility for different vehicle types.
Solution Approach 2:
The conversion system is designed to be dynamically reversible, allowing the vehicle to switch between IC engine operation and electric motor operation. The transmission assembly and housing are configured to accommodate both power sources, enabling flexible adaptation to different market segments and usage requirements.
3Volume of moving object
If compact housing design is used, then space constraints are reduced, but thermal management becomes challenging
Solution Approach 1:
The cooling channels are merged directly into the housing structure of the transmission assembly, eliminating the need for separate external cooling systems. This integration achieves effective thermal management within the compact housing volume by utilizing the housing walls themselves as heat dissipation pathways through strategically placed cooling channels.
4Weight of moving object
If lightweight design is used, then vehicle weight is reduced, but structural strength may be compromised
Solution Approach 1:
The housing is designed using composite construction principles, combining materials with different properties to achieve optimal balance between weight and strength. The housing structure incorporates reinforced sections at critical load-bearing points while maintaining lightweight construction in non-critical areas, achieving both weight reduction and structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The conversion assembly provides a cost-effective, lightweight, and efficient solution for converting IC vehicles to electric, maintaining optimal torque and speed, with improved thermal management and flexibility for different market segments, while allowing easy restoration to IC power.
Implementation Method 1
housed in a compact design with natural air cooling
Data Source
AI summary
A multi wheeled vehicle includes: a body frame that includes a head pipe; a conversion assembly that includes an electric machine operatively connected to a transmission assembly; and a housing configured to accommodate at least one electronic component and at least one electrochemical cell, the housing being attached to the electric machine, the conversion assembly being mounted to a front lower portion of the body frame by means of one or more engine mounting brackets, and the conversion assembly being disposed below a fuel tank with at least a portion of the conversion assembly being overlapping a side cover of the multi wheeled vehicle in a vehicle side view.