Electric Motorbike Conversion Layout With Integrated Cooling
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Solution Overview
Problem
Existing electric motorbikes do not effectively utilize the components and design of traditional petrol engine motorcycles for conversion, lacking cost-effective and design-preserving conversion methods.
Innovation Solution
A conversion device that replaces the petrol engine and swingarm with an electric motor and swingarm, integrates the battery into existing chassis spaces, and includes a cooling system for the electric motor and controller, maintaining the original motorcycle's appearance and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric motorbikes are designed from conception with electric components, then the vehicle can be optimized for electric propulsion, but the development costs and manufacturing complexity increase significantly
Solution Approach 1:
Instead of designing electric motorbikes from scratch with electric components, the patent inverts the approach by taking existing petrol motorbike designs and converting them to electric. This allows leveraging the proven mechanical architecture, chassis design, and component layouts of traditional motorbikes while replacing only the powertrain elements (engine with electric motor, fuel tank with battery), thereby reducing development complexity and manufacturing costs.
Solution Approach 2:
The patent creates a universal conversion kit that can be applied to multiple petrol motorbike models. The conversion system uses standard components (electric motor, battery, controller, cooling system) that can be adapted to different chassis types, making the solution multi-functional and applicable across various original motorbike designs, thus reducing overall development complexity.
2Adaptability or versatility
If conversion kits are designed to preserve the original petrol motorbike appearance, then customer acceptance increases, but the integration of electric components becomes more difficult
Solution Approach 1:
The conversion system is divided into separate modular segments: electric motor assembly, battery pack, controller unit, and cooling system. Each segment can be independently installed and positioned to fit within the existing motorbike frame without requiring complete redesign of the bodywork, thus preserving the original appearance while simplifying manufacturing integration.
Solution Approach 2:
The electric components are nested within the existing motorbike structure. The battery is positioned in the fuel tank space, the electric motor replaces the engine in the same location, and the cooling system utilizes existing airflow paths. This nesting approach allows the conversion components to be integrated without altering the external appearance of the original motorbike.
3Ease of manufacture
If existing petrol motorbike components are used for conversion, then manufacturing costs decrease, but the compatibility and reliability of the conversion may be compromised
Solution Approach 1:
The patent introduces a controller as an intermediary component that mediates between the electric motor and the existing motorbike systems (transmission, braking, suspension). This controller ensures proper coordination and compatibility, maintaining reliability while allowing the use of existing mechanical components. The controller acts as an adapter that bridges the electric and mechanical systems.
4Temperature
If cooling systems are added for electric motor and controller, then thermal management is improved, but the device complexity increases
Solution Approach 1:
The cooling system is designed to utilize the existing airflow generated by the motorbike's operation. The electric motor and controller are positioned to be cooled by the natural airflow over the vehicle body, eliminating the need for separate active cooling mechanisms. The system essentially cools itself using the environment already present during motorbike operation, thus improving thermal management without significantly increasing complexity.
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 device achieves cost savings and maintains the original motorcycle design while enhancing durability and reliability through the use of compatible components and improved cooling systems.
Implementation Method 1
a propeller (25) for cooling attached to the shaft of the electric motor (10), a first spiral-shaped casing (26) covering the electric motor and having an external opening for the suction of external air and the air flow generated by the rotation of the propeller around the electric motor cooling it
Data Source
Figure 1
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Figure 4~9
AI summary
The main object of the device of the invention is the redesign for the conversion of a motorbike with a combustion engine to an electric motor by replacing components of the motorbike so that the external appearance can be similar to the original concept, saving costs in development and manufacture by using many components compatible with the petrol model. In addition, improvements are added for the cooling of the electric motor, the motor controller and the battery. There are now electric motorbikes conceptualised from the outset with an electric motor and the arrangement of the electrical elements such as the motor and batteries to run them arranged in the chassis of the motorbike from its conception at the design stage. Other manufacturers have opted to take advantage of architectures from motorbikes with petrol engines to make electric vehicles. Our invention falls into the latter group, taking advantage of the design of an existing petrol motorbike, eliminating the elements related to the vehicle's combustion system and, using reverse engineering techniques, integrating the necessary components to convert it into an electric vehicle.